Specification
Title of Invention: Method of Producing Shaped Steel
Changing in Cross-Sectional Shape in Longitudinal
5 Direction and Roll Forming Apparatus for Same
Technical Field
[0001] The present invention relates to a method and
apparatus for roll forming for producing a shaped steel
10 which varies in cross-sectional shape in the longitudinal
direction.
Background Art
[0002] As a method of producing a hat-shaped steel,
which is one type of shaped steel, press forming using a
15 punch and die is widely known. In bending into a hat
shape by press forming, the problem of springback, that
is, the sheet material trying to return to its original
state due to the reaction force when the press pressure
is removed, easily arises, and therefore in the past,
20 countermeasures for suppressing springback have been
studied.
[0003] In this regard, in recent years, application of
high tensile steel has been increasing. As one example,
in the automobile industry, it is believed that reduction
25 of the weight of the vehicle body will lead to reduction
of the amount of emission of CO2 and therefore high
tensile steel is being proactively used for the vehicle
body material. For this reason, on the production floor
of shaped steels, the problem of the springback due to
30 the high strength characteristics of steel materials has
been surfacing. Furthermore, in recent years, high
tensile steel which has an over 980 MPa tensile strength
has also been being produced. With general press forming,
it is difficult to produce a hat-shaped steel as designed
35 from such high tensile steel.
[0004] As another method of producing a shaped steel,
the roll forming method is known. Roll forming is, for
- 2 -
example, a continuous bending process which runs a strip,
which is taken out from a coil, through roll units
provided at a plurality of successively arranged
stations. Roll forming is, in particular, suitable for
5 forming H-beams, L-beams, and other steel products and
pipes and other long products with constant crosssectional
shapes in the longitudinal direction. On the
other hand, roll forming, unlike press forming (drawing),
is not .suited for forming a shaped steel which varies in
10 cross-sectional shape in the longitudinal direction.
[0005] PLTs 1 to 3 disclose the art of roll forming to
produce a shaped steel which varies in cross-sectional
shape in the longitudinal direction by variable control
of the roll widths of split rolls. However, the roll
15 forming process and apparatus disclosed in PLTs 1 to 3
have the problem of a complicated structure and method of
control of the apparatus. For this reason, it is
difficult to convert existing facilities for use for
working the inventions of PLTs 1 to 3. Introduction of
20 new facilities is necessary, and therefore the cost
becomes high.
[0006] Further, if, as in the inventions of PLTs 1 and
3, broadening the roll widths of the split rolls during
roll forming, there are the problems that only the corner
25 parts at the front sides of the rolls will linearly
contact the steel sheet material and, in high tensile
steel or other materials, springback will occur unevenly
in the longitudinal direction and the material will be
distorted etc. in the longitudinal direction.
30
Citations List
Patent Literature
[0007] PLT 1: Japanese Patent Publication No. H10-
314848 A
35 PLT 2: Japanese Patent Publication No. H7-88560 A
PLT 3: Japanese Patent Publication No. 2009-500180A
- 3 -
Summary of Invention
Technical Problem
[0008] The present invention was made to solve the
above problem and has as its object to provide art which
5 enables production of a shaped steel which varies in
cross-sectional shape in the longitudinal direction by
simple roll forming without the need for complicated
control and apparatuses such as in the prior art.
[0009] Further, another object of the present
10 invention is to provide art which for example enables
elimination of uneven springback in the longitudinal
direction and enables suppression of buckling of the
flange parts when producing a shaped steel, which varies
in cross-sectional shape in the longitudinal direction,
15 by roll forming.
Solution to Problem
[0010] To solve the above-mentioned problem, according
to the present invention, there is provided a method of
20 producing a shaped steel which varies in cross-sectional
shape in the longitudinal direction from a sheet by roll
forming, comprising: a step of preparing a first rolling
die which has a rotation shaft and an annular ridge part
which varies in cross-sectional shape in a
25 circumferential direction which is centered about the
rotation shaft; a step of arranging the first rolling die
so that the rotation shaft of the first rolling die
becomes perpendicular to a sheet feed direction; a step
of preparing a second rolling die which has a rotation
30 shaft and an annular groove part which varies in crosssectional
'shape"in a circumferential direction which is
centered about the^ rotation shaft; a step of arranging
the second rolling die so that a gap which is equal to a
thickness of the sheet is formed between the first
35 rolling die and second rolling die and the annular ridge
part of the first rolling die and the annular groove part
of the second rolling die engage; a step of making the
_ 4 -
first rolling die and the second rolling die rotate
synchronized; and a step of feeding a sheet between the
first rolling die and second rolling die, wherein the
side surfaces of the annular ridge part of the first
5 rolling die are provided with relief so that the gap with
respect to side surfaces of the annular groove part of
the second rolling die broadens over at least part of the
circumferential direction and inward in the radial
direction of the first rolling die, wherein the annular
10 ridge part of the first rolling die is configured so that
the relative angle between the ridgeline and the rotation
direction of the first rolling die varies at least
partially in the circumferential direction, and wherein
the relief amount at the relief is set to vary in
15 accordance with the relative angle between the ridgeline
of the annular ridge part of the first rolling die and
the rotation direction of the first rolling die.
[0011] Furthermore, the present invention has as its
gist a roll forming apparatus for roll forming use for
20 producing a shaped steel which varies in cross-sectional
shape in the longitudinal direction from a sheet,
comprising: a first rolling die which has a rotation
shaft and an annular ridge part which varies in crosssectional
shape in a circumferential direction which is
25 centered about the rotation shaft, the first rolling die
arranged so that the shaft of the first rolling die
becomes perpendicular to a sheet feed direction; a second
rolling die which has a rotation shaft and an annular
groove part which varies in cross-sectional shape in a
30 circumferential direction which is centered about the
rotation -shaft, -the second rolling die arranged so that
the rotation shaft of the second rolling die becomes
parallel to the rotation shaft of the first rolling die;
and a drive device which synchronizes and rotationally
35 drives the first rolling die and the second rolling die,
the first rolling die and second rolling die being
arranged relatively so that a gap which is equal to a
- 5 -
thickness of the sheet is formed between the two and the
annular ridge part of the first rolling die and the
annular groove part of the second rolling die engage,
wherein the side surfaces of the annular ridge part of
5 the first rolling die are provided with relief so that
the gap with respect to side surfaces of the annular
groove part of the second rolling die broadens over at
least part of the circumferential direction and inward in
the radial direction of the first rolling die, wherein
10 the annular ridge part of the first rolling die is
configured so that the relative angle between the
ridgeline and the rotation direction of the first rolling
die varies at least partially in the circumferential
direction, and wherein the relief amount at the relief is
15 set to vary in accordance with the relative angle between
the ridgeline of the annular ridge part of the first
rolling die and the rotation direction of the first
rolling die.
20 Advantageous Effects of Invention
[0012] According to the present invention, by using a
first rolling die having an annular ridge part which
varies in cross-sectional shape in the circumferential
direction and a second rolling die having an annular
25 groove part which receives the annular ridge part of the
first rolling die while maintaining a gap with the
annular ridge part of the amount of thickness of the
shaped steel, by simple control for making at least the
first and second rolling dies rotate synchronized, a
30 shaped steel with a cross-sectional shape which varies in
the longitudinal direction can be produced. Accordingly,
complicated control such as variable control of the roll
widths of split rolls for broadening the width of the
cross-section becomes unnecessary. Further, it is
35 possible to realize the rolling forming apparatus of the
present invention by changing the rolls of existing roll
forming apparatuses to the first and second rolling dies.
- 6 -
[0013] Further, when using a first rolling die having
an annular ridge part which varies in cross-sectional
shape in the circumferential direction and a second
rolling die having an annular groove part which receives
5 the annular ridge part of the first rolling die while
maintaining a gap with the annular ridge part of the
amount of thickness of the shaped steel, sometimes
interference will occur between the rolling dies.
According to the present invention, it is possible to
10 prevent such interference by providing relief which
varies in relief amount in accordance with a relative
angle with a rotation direction of the rolling dies.
[0014] In addition, by using the first and second
rolling dies which have the above-mentioned roll barrel
15 parts, even if the cross-sectional shape varies in the
longitudinal direction, shaping is possible in the state
with a constant gap between the two rolling dies, and
therefore it is possible to eliminate the uneven
occurrence of springback in the longitudinal direction,
20 for example, due to an uneven gap, and possible to
suppress buckling of the flange parts.
Brief Description of Drawings
[0015] [FIG. 1A] FIG. 1A is a perspective view of a
25 hat-shaped steel which varies in cross-sectional shape in
the longitudinal direction, as seen from above.
[FIG. IB] FIG. IB is a perspective view of a hat-shaped
steel which varies in cross-sectional shape in the
longitudinal direction, as seen from below.
30 [FIG. 2] FIG. 2 is a schematic perspective view of a
multistage roll forming apparatus according to a first
embodiment of the present invention.
[FIG. 3] FIG. 3 is a vertical view of a roll unit of the
multistage roll forming apparatus of FIG. 2.
35 [FIG. 4] FIG. 4 is a disassembled perspective view of a
pair of top and bottom rolling dies of the roll unit of
FIG. 3.
- 7 -
[FIG. 5A] FIG. 5A is a view showing a bending process at
different stages of the multistage roll forming apparatus
of FIG. 2 and a view.showing a step of forming flanges of
a hat-shaped steel.
5 [FIG. 5B] FIG. 5B is a view showing a bending process at
different stages of the multistage roll forming apparatus
of FIG. 2 and a view showing a step of forming a top wall
of a hat-shaped steel.
[FIG. 6] FIG. 6 is a schematic perspective view for
10 explaining the action in one roll unit.
[FIG. 7A] FIG. 7A is a perspective view of a hat-shaped
steel which has a bead.
[FIG. 7B] FIG. 7B is a perspective view of rolling dies
which form the hat-shaped steel of FIG. 7A.
15 [FIG. 8] FIG. 8 shows rolling dies according to a second
embodiment.
[FIG. 9] FIG. 9 is a partial cross-sectional view of the
rolling dies of FIG. 8.
[FIG. 10] FIG. 10 is a chart which shows a minimum gap
20 when providing relief at the rolling dies.
[FIG. 11] FIG. 11 is a partial cross-sectional view of
rolling dies of a comparative example.
[FIG. 12A] FIG. 12A is a perspective view which shows
interference between a top roll and a bottom roll when
25 not providing relief and shows together a hat-shaped
steel.
[FIG. 12B] FIG. 12B is a perspective view which shows
interference between a top roll and a bottom roll when
not providing relief and shows together a hat-shaped
30 steel.
[FIG. 13] FIG. 13 is a chart which shows the effect of
the minimum gap on an amount of difference.
[FIG. 14] FIG. 14 is a schematic partial cross-sectional
view of rolling dies for explaining a reverse bending
35 phenomenon due to over run.
[FIG. 15] FIG. 15 is a developed view of the outer
circumferential surface of a bottom roll and a view which
- 8 -
shows a relationship with and the relief amount.
[FIG. 16] FIG. 16 is a partially enlarged view of a
bottom roll which shows a relief amount x, a side wall •
angle 0 of a shaped steel, and a height H of an annular
5 ridge part.
[FIG. 17] FIG. 17 is a partial vertical cross-sectional
view of top and bottom rolls which is cut along a plane
which includes the center axes of the top and bottom
rolls.
10 [FIG. 18] FIG. 18 is a perspective view which shows
another example of a multistage roll forming apparatus.
[FIG. 19] FIG. 19 is a view which shows a bending process
at different stages of the multistage roll forming
apparatus of FIG. 18.
15 [FIG. 20] FIG. 20 is a view which shows a start point of
relief provided at an annular ridge part of a bottom
roll.
[FIG. 21] FIG. 21 is a view which shows a relationship
between L/H and a minimum gap.
20 [FIG. 22] FIG. 22 is a view which shows the relationship
between L/H and an amount of difference from a target
shape.
[FIG. 23A] FIG. 23A is a perspective view of a shaped
steel according to a third embodiment.
25 [FIG. 23B] FIG. 23B is a perspective view of rolling dies
according to a third embodiment which is shown together
with the shaped steel of FIG. 23A.
[FIG. 24A] FIG. 24A is a perspective view of a shaped
steel according to a fourth embodiment.
30 [FIG. 24B] FIG. 24B is a perspective view of rolling dies
according to a fourth embodiment which is shown together
with the shaped steel of FIG. 24A.
[FIG. 25A] FIG. 25A is a perspective view of a shaped
steel according to a fifth embodiment.
35 [FIG. 25B] FIG. 25B is a perspective view of rolling dies
according to a fifth embodiment which is shown together
with the shaped steel of FIG. 25A.
- 9 -
[FIG. 26A] FIG. 2 6A is a perspective view of a shaped
steel according to a sixth embodiment.
[FIG. 2 6B] FIG. 26B is a perspective view of rolling dies
according to a sixth embodiment which is shown together
5 with the shaped steel of FIG. 26A.
[FIG. 27A] FIG. 27A is a perspective view of a shaped
steel according to a seventh embodiment.
[FIG. 27B] FIG. 27B is a perspective view of rolling dies
according to a seventh embodiment which is shown together
10 with the shaped steel of FIG. 27A.
[FIG. 28A] FIG. 28A is a perspective view of a shaped
steel according to an eighth embodiment.
[FIG. 28B] FIG. 28B is a perspective view of rolling dies
according to an eighth embodiment which is shown together
15 with the shaped steel of FIG. 28A.
[FIG. 29A] FIG. 29A is a perspective view of a shaped
steel according to a ninth embodiment.
[FIG. 29B] FIG. 29B is a perspective view of rolling dies
according to a ninth embodiment which is shown together
20 with the shaped steel of FIG. 29A.
[FIG. 30A] FIG. 30A is a perspective view of a shaped
steel according to a 10th embodiment.
[FIG. 30B] FIG. 30B is a perspective view of of rolling
dies according to a 10th embodiment which is shown
25 together with the shaped steel of FIG. 30A.
[FIG. 31A] FIG. 31A is a perspective view of a shaped
steel according to an 11th embodiment.
[FIG. 3IB] FIG. 3IB is a perspective view of rolling dies
according to an 11th embodiment which is shown together
30 with the shaped steel of FIG. 31A.
Description of Embodiments
[0016] Below, a method of production of a shaped steel
which varies in cross-sectional shape in the longitudinal
35 direction and a roll forming apparatus for the same
according to preferable embodiments of the present
invention will be explained in detail, while referring to
- 10 -
the attached drawings. However, the embodiments explained
below shall not cause the present invention to be
interpreted limited in technical scope in any way.
[0017]
5 First, the shaped steel produced in the present
embodiment will be explained. The shaped steel which is
shown in FIGS. 1A and IB is one example of a hat-shaped
steel of a saddle shape which varies in cross-sectional
shape in the longitudinal direction (for example, the
10 metal stock axis direction). FIG. 1A is a perspective
view of the hat-shaped steel seen from the upper side,
while FIG. IB is a perspective view seen from the lower
side. The hat-shaped steel 1 comprises a top wall, side
walls which extend along the two side edge parts of the
15 top wall, and flanges which extend along the edge parts
at the opposite sides of the side walls, and has a crosssection
vertical to the longitudinal direction of the
hat-shaped steel 1 (lateral cross-section) which is
substantially hat shaped.
20 [0018] The hat-shaped steel 1 further has ^portions
10a, 10b having top wall width of LI, a portion 11 having
top wall width of L2 (>L1), and tapered transition
portions 12a and 12b having expanding (or contracting)
top wall width of Ll to L2. The hat-shaped steel 1 has
25 hat-shape horizontal cross-sections with side walls which
flare outward at the portions 10a to 10b. The side walls
may have gradient angles which differ at the portions 10a
to 10b or which are the same at the portions 10a to 10b.
Further, the thickness of the steel shape can, for
30 example, be set to various thicknesses according to the
specifications, applications, etc. However, in the
present embodiment, the different portions 10a to 10b are
not individually shaped and joined by welding etc., but
are integrally shaped from a single sheet or strip by
35 roll forming. Therefore, the boundary lines between
portions of FIG. 1 are lines for convenience of
explanation and are not join lines or bend lines.
- 11 -
[0019] Furthermore, the flanges 13 formed at the
opening part of the bottom surface side along the
longitudinal direction are also obtained by bending the
sheet or strip by roll forming. Further, the corner parts
5 which formed by bending can, for example, have chamfered
shapes or rounded shapes such as shown in FIG. 1.
[0020] The type and strength of the material are not
particularly limited. All metal materials which can be
bent can be covered. As examples of the metal material,
10 there are carbon steel, alloy steel, nickel-chromium
steel, nickel-chromium-molybdenum steel, chromium steel,
chromium-molybdenum steel, manganese steel, and other
steel materials. If based on strength, steel with tensile
strengths of 340 MPa or less can be roughly classified as
15 general steel and steel with higher strengths can be
roughly classified as high tensile steel, but in the
present embodiment, either can be applied. Furthermore,
high tensile steel includes steel of for example the 590
MPa grade or 780 MPa grade. Currently, steel of the 980
20 MPa grade or 1180 MPa grade called "ultra high tensile
steel" are being produced. Regarding ultra high tensile
steel, sometimes bending into hat shapes becomes
difficult with conventional press forming (drawing), but
with the roll forming of the present embodiment, 980 MPa
25 or more ultra high tensile steel can also be applied.
Furthermore, as examples of materials other than steel
materials, there are the poorly malleable materials
including titanium, aluminum, or magnesium or their
alloys.
30 [0021] Next, the roll forming apparatus for producing
a steel - strap e which varies in cross-sectional shape in
the longitudinal direction will be explained. FIG. 2
shows a multistage roll forming apparatus 2 for producing
the above-mentioned hat-shaped steel as one embodiment of
35 a roll forming apparatus. The multistage roll forming
apparatus 2 comprises, for example, a plurality of roll
units 20a to 20k which are successively arranged in the
- 12 -
sheet or strip feed direction. Due to this, a long sheet
or strip M is conveyed from the upstream side roll unit
20k to the downstream side roll unit 20a while bending it
in stages to obtain the final target product shape. The
5 finally shaped sheet or strip M is successively cut into
product units.
[0022] The rolling dies of the roll unit 20a of the
downstream-most station {final station) (below, sometimes
referred to as the "finishing rolls") are shaped
10 corresponding to the target product shape. The rolling
dies of the stations at the upstream side from the
finishing rolls are designed so that intermediates which
approach the final product shape in stages the further
toward the downstream side are formed at the different
15 stages. FIG. 2 shows one example of the rolling dies
which form a final product from a sheet or strip M in 10
stages. At each of the first station to the fifth station
which perform the first half bending process, the roll
units 20j to 20f have the dies which have the projecting
20 shape roll barrel parts at the top side and the dies
which have the recessed shape roll barrel parts at the
bottom side.
[0023] On the other hand, at each of the sixth station
to the 10th station which perform the second half bending
25 process, the roll units 20e to 20a have the dies which
have the annular ridge parts at the bottom side and the
dies which have the annular groove parts at the top side.
Further, the entry station (roll unit 20k: 0th station)
to fifth station (roll unit 20f) are the first half
30 process for forming the flanges 13 (flange bending) and
the sixth-station (roll unit 20e) to the final station or
the 10th station (roll unit 20a) are the second half
process for forming the top wall of the hat-shaped steel
1 (top wall bending).
35 [0024] The roll unit 20k of the entry station has
rolling dies having plain cylindrical shape arranged at
both the top and bottom. Further, the roll units 20j to
- 13 -
20f from the first station to the fifth station become
gradually smaller in diameters in the directions toward
the ends at both two end portions of the top rolls, while
the two end portions of the roll barrel parts of the
5 bottom rolls become gradually larger in diameter in the
directions toward the ends. Further, the inclination
angles of the two end portions of the dies become sharper
in order from the first station to the fifth station. At
the roll unit 20f of the fifth station, the two ends of
10 the sheet or strip M are bent about 90°, whereupon the
flanges 13 are formed. The dies have, in the
circumferential direction, parts of narrow x^idths and
wide widths and parts of tapers of increasing/decreasing
width, at the centers of the 'roll barrel parts, so that
15 flanges 13 of the portions 10a to 10b of the shaped steel
are formed.
[0025] On the other hand, the roll units 20e to 20a
from the sixth station to the final station have bottom
rolls with annular ridge parts in which the center of the
20 roll barrel parts are raised in projecting shapes and
have top rolls with annular groove parts in which the
center of the roll barrel parts are sunk in recessed
shapes. Further, more specifically, the annular ridge
parts of the bottom rolls and the annular groove parts of
25 the top rolls comprises narrow width parts, wide width
parts, and tapered parts with increasing width/decreasing
width, arranged in the circumferential direction, so that
the top walls of the portions 10a to 10b of the hatshaped
steel 1 are formed.
30 [0026] The inclination angles of the side surfaces of
the annular ridge parts and annular groove parts of the
rolls become sharper in the order from the sixth station
to the final station. At the roll unit 20a of the final
station, the side walls of the sheet or strip M are bent
35 about 90° whereby the top wall of the hat is formed.
However, the configuration of the rolling dies which is
shown in FIG. 2 is one example. The number of units
if
- 14 _
arranged can be suitably changed. Further, the rolling
dies which are arranged at the upstream side of the
finishing rolls can be further suitably changed in
shapes.
5 [0027] Note that, in the present embodiment, the
cross-sectional shape is not just increased in width.
After the portion 11 where the width becomes maximum,
portions 12b and 10b which are decreased in widths are
formed by the rolls, and therefore the intervals between
10 the roll units 20a to 20k are set to at least the lengths
of the products.
[0028] Next, the configuration of the roll units 20a
to 20k will be explained. FIG. 3 shows the overall
structure of the roll unit 20a in which the finishing
15 rolls are assembled. The roll unit 20a is provided with a
first rolling die which has a rotation shaft 31 which
extends in a sheet or strip feed direction, for example,
the horizontal direction (below, referred to as a "bottom
roll 3") and a second rolling die which has a rotation
20 shaft 41 which is parallel to the shaft 31 of the bottom
roll 3 and faces the bottom roll 3 across a slight gap
(below, referred to as a "top roll 4").
[0029] The shafts 31 and 41 of the rolls 3 and 4 are,
for example, rotatably supported by ball bearings or
25 other bearing mechanisms 5 at stands or other support
members 51. The rolls 3 and 4 are supported to be able to
be raised and lowered and can be adjustable in distance
of separation of the rolls. Furthermore, it is also
possible to use a hydraulic pressure cylinder or other
30 pressing device to enable adjustment of the pressing
forces of the top and bottom rolls 4 and 3.
[0030] The top and bottom rolls 4 and 3 are driven to
rotate synchronized by a gear set 52. The gear set 52
comprises gears 52a and 52b which are coupled with the
35 shafts 31 and 41 respectively and are engaged with each
other. FIG. 3 shows, as one example of the gear set 52,
the top and bottom gears 52a and 52b which are formed by
- 15 -
spur gears. Further, at one end of the shaft 31 of the
bottom roll 3, for example, a drive motor or other drive
device 53 is connected. If this drive device 53 makes the
bottom roll 3 rotate, the top roll 4 is driven to rotate
5 through the gear set 52. At this time, for example, by
setting the top and bottom gear ratios the same, the top
and bottom rolls 4 and 3 rotate synchronously at the same
peripheral speeds. That is, the gear set 52 is also the
synchronized rotation mechanism of the top and bottom
10 rolls 4 and 3.
[0031] The gear set 52 only need make the top and
bottom rolls 4 and 3 rotate synchronously by the same
peripheral speed. The gears need not be spur gears such
as shown in FIG. 3 of course. Furthermore, it need not be
15 configured to drive the top roll 4 through the gear set
52. Individual drive mechanisms may also be connected to
the top and bottom rolls 4 and 3. It is also possible to
use an inverter controllable drive motor to adj ust the
rotational speed.
20 [0032] The top and bottom rolls 4 and 3 which are
arranged at the final station are shaped corresponding to
the target product shape. Specifically, as shown in FIGS.
3 and 4, the bottom roll 3 has flank parts 32 which roll
the top surfaces of the flanges 13 and an annular ridge
25 part 33 which rises up at the center portion in the axial
direction of the flank parts 32 from the outer surface in
a projecting shape and rolls the inside part of the hat
shape.. The cross-sectional shape of the annular ridge
part 33 exhibits a frustoconical shape which varies in
30 the circumferential direction corresponding to the hat
shape of the 'finished product.
[0033] That is, the annular ridge part 33 has a region
33a which is set in width of the outer circumferential
surface to the first roll width, a region 33b which is
35 set in width of the outer circumferential surface to the
second roll width, and tapered regions (in the following
explanation, sometimes called the "transition parts") 33c
- - 16 -
and 33d which are arranged between the regions 33a and
33b and vary in widths of the outer circumferential
surfaces from the first roll width to the second roll
width. The left and right side surfaces of the annular
5 ridge part 33 form slanted surfaces which expand to the
outward sides the further toward the shaft 31 side.
Further, the width and height of the annular ridge part
33 and the inclination angle of the side surfaces are
dimensions which correspond to the width and height and
10 the inclination angle of the target hat shape.
Furthermore, the corner parts (ridgelines) at the
outsides of the annular ridge part 33 and the corner
parts at the insides of the flank parts 43 (recessed
ridgelines) are rounded or are chamfered. Note that, FIG.
15 4, like FIG. 1, shows the borderlines of the regions 33a,
33b, 33c, and 33d for convenience of explanation.
[0034] The region 33b of the annular ridge part 33
forms the portion 11 of the width L2 of the hat-shaped
steel 1, while the regions 33c and 33d form the tapered
20 portions 12a and 12b of the hat-shaped steel 1.
Therefore, the arc length of the region 33b is set to the
length of the portion 11, while the arc lengths of the
regions 33c and 33d are set to lengths of the portions
12a and 12b. On the other hand, the region 33a of the
25 annular ridge part 33 forms both the portions 10a and 10b
of the hat-shaped steel 1. Therefore, the arc length of
the region 33a is set to a length corresponding to the
sum of the lengths of the portions 10a and 10b. In this
case, the intermediate point which equally divides the
30 region 33a becomes the start point of the roll. However,
when a 'continuous sheet or strip M for continuous forming
is used and the finally shaped product is successively
cut downstream of the apparatus, regions giving cutting
margins may also be added to the regions 33a. In this
35 case, a mark for indicating the cutting position (for
example, small hole, projection, etc.) may also be formed
at the surface of the sheet or strip M.
- 17 -
[0035] On the other hand, the top roll 4 is formed to
face the roll barrel part of the bottom roll 3 across a
gap of the amount of thickness of the hat-shaped steel 1.
Therefore, the top roll 4 has an annular groove part 42
5 which rolls the outside bottom surface of the hat shape
and flank parts 43 which are formed at the two sides of
the annular groove part 42 and roll the outside surfaces
of the hat shape and the bottom surfaces of the flanges
13. The inside surfaces of the annular groove part 42 are
10 also formed to face the side surfaces of the annular
ridge part 33 of the bottom roll 3 through a gap of the
amount of thickness of the hat-shaped steel 1. Due to
this, the annular groove part 42 of the top roll 4 varies
in cross-sectional shape in the circumferential
15 direction.
[0036] The side surfaces of the annular groove part 42
of the top roll 4, like the annular ridge part 33 of the
bottom roll 3, are formed with the region 43b which forms
the portion 11 of the hat-shaped steel 1, the regions 43c
20 and 43d which form the tapered portions 12a and 12b
respectively, and the region 43a which forms the portions
10a and 10b, in the circumferential direction.
Furthermore, in the same way as the annular ridge part
33, the intermediate point which equally divides the
25 region 43a forms the start point of the rolls, and
therefore when assembling the top and bottom rolls 4 and
3 in the apparatus, the top and bottom rolls 4 and 3 are
positioned in the rotation direction at the positions
where their start points face each other (same phase).
30 [0037] If viewed in the shaft direction, the annular
ridge part '33 of the bottom roll 3 and the bottom surface
of the annular groove part 42 of the top roll 4 have
cylindrical surfaces with outer circumferential surfaces
of the same diameters. Due to this, if making the top and
35 bottom rolls 4 and 3 rotate by the same peripheral
speeds, the relative phase of the top and bottom rolls 4
and 3 will not vary. In the case of a pair of top and
- 18 -
bottom rolls, so-called "slip" is liable to cause the
relative phase of the turning top and bottom rolls 4 and
3 to vary. If the rolls have cross-sectional shapes which
are constant in the circumferential direction, "slip"
5 does not become that much of a problem, but the top and
bottom rolls 4 and 3 of the present embodiment have
regions which vary in cross-sectional shape in the
circumferential direction, and therefore if "slip" causes
the top and bottom rolls 4 and 3 to become offset in
10 phase, the finished product is liable to become off in
thickness from the design value and the top and bottom
rolls are liable to collide. Therefore, in the present
embodiment, it is important to make the top and bottom
rolls 4 and 3 turn without changing their relative
15 phases. The gear set 52 which forms the above-mentioned
synchronized rotation mechanism also has the role of
preventing the relative phase of the turning top and
bottom rolls 4 and 3 from changing.
[0038] Note that, the top and bottom rolls 4 and 3
20 only have to be made from a material which is higher in
rigidity than the sheet or strip M at the roll barrel
parts. The material is not limited. Further, it is also
possible to arrange the rolling die which has the annular
ridge part at the top side and the rolling die which has
25 the annular groove part at the bottom side.
[0039] FIG. 3 shows a roll unit 20a which including
finishing rolls, but the other roll units 20b to 20k
which are arranged upstream of the finishing rolls may be
made the same in configuration as the roll unit 20a
30 except for the shapes of the rolls being different. For
this reason, detailed explanations of the other roll
units 20b to 20k will be omitted.
[0040] The present invention is not limited to the
following dimensions, but to further deepen
35 understanding, an example of the dimensions of the
different regions of the bottom roll 3 will be shown.
First, the radius of the bottom roll 3 to the outer
- 19 -
circumferential surface is 500 mm at the annular ridge
part 33 and 450 mm at the flank parts 32. The difference
of the two corresponds to the height of the hat shape.
The width of the outer circumferential surface of the
5 region 33a is 50 mm, while the arc length is 400 mm.
Further, the width of the outer circumferential surface
of the region 33b is 80 mm, while the arc length is 400
mm. Further, the regions 33c and 33d have arc lengths of
300 mm and expand in width or contract in width by a 15°
10 gradient angle (relative angle between ridgeline of
annular ridge part 33 and rotation direction of bottom
roll 3 or relative angle between recessed ridgeline at
inside of flank parts 43 and rotation direction of top
roll 4). The top roll 4 faces the bottom roll 3 through a
15 gap of 2 mm.
[0041] Next, the method of using the multistage roll
forming apparatus 2 to produce the hat-shaped steel 1
will be explained. First, the top and bottom rolls 4 and
3 of the roll units 20a to 20k are made to rotate at a
20 predetermined speed and the sheet or strip M is fed to
the roll unit 20k of the entry station. For example, as
the steel sheet or strip M, it is possible to use steel
sheet which is sent from an upstream rolling process or
use a strip which is wound in a coil shape. At this time,
25 the sheet or strip M is fed so that the length direction
becomes perpendicular to the axial direction of the top
and bottom rolls 4 and 3 and is roll formed in the length
direction of the sheet or strip M. The sheet or strip M
(intermediate) which is fed out from the roll unit 20k is
30 conveyed by the rotational operation of the top and
bottom rolls 4 and 3 to the roll unit 20j of the next
station. Further, it is roll formed by this second stage
roll unit 20j along the length direction and is further
conveyed to the roll unit 20i of the next station.
35 [0042] Note that, when continuously roll forming the
sheet or strip M, the roll units 20a to 20k of the
different stations may be used to form it while applying
- 20 -
back tension and/or forward tension. Further, they may
form it by cold, warm, or hot roll forming.
[0043] FIGS. 5A and 5B show the state where the sheet
or strip M is bent'into a hat shape in stages at the 10
5 stages of the roll units 20a to 20k. FIG. 5A shows the
state in which the flanges 13 are formed by using the
roll units 20k to 20a at the first to fifth stations.
FIG. 5B shows the state in which the top wall of the hatshaped
steel 1 is formed by using the roll units 20e to
10 30a at the sixth to final stations. Note that, FIGS. 5A
and 5B are cross-sectional views of the portion 10a of
the hat-shaped steel 1, but the other portions 10b, 11,
12a, and 12b are also bent in stages to the hat shape at
the 10 stages of the roll units 20a to 20k. Therefore,
15 the material (intermediate) which is roll formed at the
ninth station becomes a shape close to the final product
and is finally shaped by the 10th finishing roll.
[0044] The state where the finishing rolls perform the
final forming operation is shown in FIG. 6. In the sheet
20 or strip M (intermediate) which is conveyed from
upstream, the width Ll portion 10a is formed by the back
half part from the start point to the regions 33a and 43a
of the first top and bottom rolls, then the gradually
increasing width portion 12a is formed by the regions 33c
25 and 43c and, furthermore, the width L2 portion 11 is
formed by the regions 33b and 43b. Next, the gradually
decreasing width portion 12b is formed by the regions 33d
and 43d and finally the width Ll portion 10b is formed by
the front half part from the start point of the regions
30 33a and 43a. At this time, the back half part of the
regions 33a and- 43a forms the width Ll portion 10a of the
next product.
[0045] The finished product which is fed out from the
finishing roll after final shaping is completed is cut at
35 the position forming the terminating end (that is, the
end part of the portion 10b) and, is conveyed to other
next step, for example, to the product inspection step.
- 21 -
The cutting position can be automatically discerned by
for example detecting a mark (for example, small hole,
projection, etc.) which is formed at intervals in the
length direction of the sheet or strip M, by a sensor.
5 The mark may be provided at intervals corresponding to
the lengths of the finished products at the sheet or
strip M in advance or may be provided during roll
forming. As the method of providing a mark during roll
forming, using top and bottom rolls 4 and 3 which are
10 formed with projections forming the mark at a position
corresponding to the starting point of the rolls so as to
transfer a mark along with bending to the hat shape may
be mentioned as one example. In addition to a mark, a
predetermined relief shape may be formed on the surface
15 of the roll barrel part so as to form a bead, embossing,
or other shape. FIGS. 7A and 7B show an example of a bead
14 and a projecting part 35 which is formed at a roll
barrel part for forming the bead 14. While not
illustrated, the top roll 4 is formed with a recessed
20 part which corresponds to the projecting part 35 though a
gap of the amount of thickness of the material. The
shapes, positions, and numbers of the beads and embossing
can be suitably changed.
[0046] According to the present embodiment, when using
25 a bottom roll 3 which has an annular ridge part 33 and a
top roll 4 which has an annular groove part which faces
the annular ridge part 33 to produce a hat-shaped steel
1, by the shapes of the annular ridge part 33 and the
annular groove part 42 being made shapes which vary in
30 cross-sectional shape in the circumferential direction, a
hat-shaped •steel 1 which varies in cross-sectional shape
(that is, the hat shape) in the longitudinal direction
can be produced by simple control for making the top and
bottom rolls 4 and 3 rotate synchronized.
35 [0047] In this way, the roll forming according to the
present embodiment does not require the complicated
control method for changing the roll widths of split
- 22 -
rolls like in the past, and therefore does not require
the introduction of new control modules for this purpose.
Accordingly, for example, it is possible to realize the
roll forming apparatus of the present embodiment by
5 changing the rolls of an existing roll forming apparatus
to the top and bottom rolls 4 and 3 of the present
embodiment.
[0048] Note that, in the multistage roll forming
apparatus 2 of FIG. 2, the roll units 20a to 20k are
10 arranged on a line, but if arranging the roll units 20a
to 20k in tandem curved in the up-down direction, it
becomes possible to produce a hat-shaped steel which is
curved in the longitudinal direction.
[0049] Furthermore, according to the present
15 embodiment, by the roll barrel part which varies in
cross-sectional shape in the circumferential direction,
the roll barrel part and material can sufficiently
contact each other in the forming operation, and
therefore for example even if the material is high
20 tensile steel, insufficient mill rigidity can be
suppressed. Accordingly, the roll forming method and
apparatus of the present embodiment can also be applied
to tensile strength 980 MPa or more ultra high tensile
steel.
25 [0050]
Next, a modification of the rolling dies which are shown
in the above-mentioned first embodiment will be
explained. In the rolling dies of the present embodiment,
as shown in FIG. 8, the outside diameter of the annular
30 ridge part 33 of the bottom roll 3 (hatched part) and the
outside diameter of the bottom surface of the annular
groove part 42 of the top roll 4 (hatched part) are the
same, and the side walls of the annular ridge part 33 of
the bottom roll 3 are provided with the later explained
35 relief. Leaving aside this feature, the top and bottom
rolls 4 and 3 of the present embodiment are substantially
the same as the top and bottom rolls 4 and 3 of the first
- 23 -
embodiment. Similar component elements are assigned the
same reference notations, and detailed explanations are
omitted.
[0051] The relief which is provided at the side
5 surfaces of the annular ridge part 33 of the bottom roll
3 will be explained in detail. FIG. 9 is a partial
vertical cross-sectional view which is cut along the
plane which includes the center axes of the top and
bottom rolls 4 and 3. In the first embodiment, the gap
10 between the facing bottom surfaces and side surfaces of
the top and bottom rolls 4 and 3 was constant over the
entire circumference in the circumferential direction,
but in the present embodiment, the side surfaces of the
annular ridge part 33 of the bottom roll 3 are offset by
15 the relief amount x to the inside of the axial direction
of the roll from the inside surface of the designed hatshaped
steel 1. By providing relief to the side surfaces
of the annular ridge part 33 in this way, the gap between
the side surfaces of the annular ridge part 33 and the
20 side surfaces of the annular groove part 42 becomes wider
the further toward the base of the annular ridge part 33,
that is, the inside in the radial direction. In the
figure, the broken line shows a side surface when not
providing the relief. In the case of the bottom roll 3 of
25 the final station, when working as one example a material
of a sheet thickness of 1.0 mm, the relief amount x is
preferably 1.4 mm or more. The method of determination of
the relief amount will be explained later.
[0052] FIG. 10 shows the result of comparison of the
30 gaps between the top and bottom rolls 4 and 3 in the case
of relief and no relief. More specifically, FIG. 10 shows
the minimum distance (minimum gap) between the side
surfaces at the different phases when designating the
start points of the top and bottom rolls 4 and 3 (see
35 FIG. 4) as 0° and making the top and bottom rolls 4 and 3
rotate in 5° increments. In particular, in the example
- 24 -
which is shown in FIG. 10, the region of about 45° to 120°
corresponds to the transition parts 33c and 43c. Further,
at about 45° to 65°, the above-mentioned gradient angle
(relative angle between ridgeline of annular ridge part
5 33 and rotation direction of bottom roll 3 or relative
angle between recessed ridgeline at inside of flank parts
43 and rotation direction of top roll 4) gradually
increases, while in the region of about 100° to 120°, the
gradient angle <|> gradually decreases. At the time of 180°
10 to 360°, the shape is symmetric, and therefore an
explanation will be omitted.
[0053] Further, the broken line of FIG. 10 shows the
case where relief is not provided, while the one-dot
chain line of FIG. 10 shows the case where relief such as
15 shown in FIG. 11 is provided at the side surfaces of the
annular ridge part 33 only at the transition part 33c.
Further, the two-dot chain line of FIG. 10 shows the case
where relief of a tapered shape such as shown in FIG. 9
is provided at the side surfaces of the annular ridge
20 part 33 over the entire circumference, while the solid
line of FIG. 10 shows the case where relief of a tapered
shape such as shown in FIG. 9 is provided at the side
surfaces of the annular ridge part 33 only at the
transition part 33c. Note that, FIG. 11 shows a
25 comparative example for the present embodiment and is a
partial vertical cross-sectional view which is cut along
the plane which includes the center axes of the top and
bottom rolls 4 and 3. In the comparative example which is
shown in FIG. 11, relief is provided so that the gap
30 between the side surfaces of the annular ridge part 33
and the side surfaces of the annular groove part 42
becomes constant in the radial direction, that is, to
cause simple parallel movement from the broken line in
the figure which shows the side surfaces when not
35 providing relief.
[0054] As will be clear from the broken line of FIG.
- 25 -
10, it is learned that when not providing relief, the
minimum gap greatly varies (decreases and increases) at
the about 45° to 65° region and the 100° to 120° region.
FIGS. 12A and 12B show results of numerical analysis
5 which show the interference between rolls when not
providing relief. The parts which are shown by hatching
show the interference regions {that is, the regions where
the rolls actually contact each other or the gap between
the rolls becomes small). Further, as shown by the one-
10 dot chain line in FIG. 10, when making only the
transition part 33c simply move in parallel to provide
the relief, the minimum gap varies at the transition
parts 33c and 43c and the minimum gap is difficult to be
maintained constant over the entire circumference.
15 [0055] On the other hand, as shown by the two-dot
chain line of FIG. 10, it is learned that when providing
relief of a tapered shape over the entire circumference,
the amount of variation of the minimum gap is small and
the gap is maintained substantially constant over 0° to
20 180° as a whole. Note that, in the above example, only the
transition parts 33c and 43c were explained, but the same
can be said for the transition parts 33d and 43d as well.
Furthermore, as shown in FIG. 10 by the solid line, it is
learned that when providing relief of a tapered shape at
25 only the transition parts 33c and 33d and not providing
relief at the other regions, the amount of variation of
the minimum gap becomes extremely small and the gap is
maintained more constant in the range of 0° to 180° as a
whole. While depending on the thickness or shape of the
30 shaped steel, the preferable minimum gap when considering
the product specifications etc. becomes the thickness of
the sheet or more. According to the present embodiment,
by providing relief at the side surfaces of the annular
ridge part 33 of the bottom roll 3, it becomes possible
35 to secure a minimum gap of the sheet thickness or more.
[0056] FIG. 13 shows the effects on the amount of
- 26 -
springback of the finished product based on the minimum
gap between the top and bottom rolls 4 and 3 in the
circumferential direction (that is, the amount of
difference from the target shape). In particular, FIG. 13
5 shows the effects at steel sheets of the 590 MPa grade,
980 MPa grade, 1180 MPa grade, and 1310 MPa grade. When
the amount of difference from the target shape is
negative, as shown at the top right in the figure, this
shows that "spring go" occurs, while when the amount of
10 difference is positive, as shown at the bottom right in
the figure, this shows that springback occurs.
[0057] As will be understood from FIG. 13, in the four
types of steel sheets of different tensile strength (590
MPa grade, 980 MPa grade, 1180 MPa grade, and 1310 MPa
15 grade), the amount of difference becomes a minus one as
the minimum gap becomes larger. This is because, as shown
in FIG. 14, due to the minimum gap becoming broader, the
sheet over runs and tensile stress occurs at the inside
parts of the shoulders of the bottom roll. Release of
20 that tensile stress causes the phenomenon of spring go.
Therefore, by providing the side surfaces of the annular
ridge part 33 of the bottom roll 3 with relief of a
tapered shape offset to become broader at the inside in
the axial direction of the roll, the minimum gap between
25 the top and bottom rolls 4 and 3 in the circumferential
direction can be maintained substantially constant.
Therefore, the amount of springback becomes uniform in
the longitudinal direction of the strip M. For this
reason, the effect is exhibited that the occurrence of
30 buckling at the flange parts can be suppressed. This is
therefore an extremely effective effect. Further, it is
possible to prevent a reduction in sheet thickness at the
base region of the annular ridge part 33 and possible to
prevent the sheet thickness from falling below a fracture
35 criteria. From the above, in the second embodiment as
well, it is possible to obtain effects similar to the
first embodiment and, furthermore, it is possible to form
- 27 -
a shaped steel which is kept down in variation in sheet
thickness.
[0058] Note that, as explained above, by providing
relief at the side surfaces of the annular ridge part 33
5 at the transition part 33c, it is possible to suppress
changes in the minimum gap between the top and bottom
rolls 4 and 3. In other words, by providing relief at the
side surfaces of the annular ridge part 33 at the regions
with a large gradient angle , it is possible to suppress
10 changes in the minimum gap. Therefore, in the present
embodiment, the relief amount x at the relief which is
provided at the side surfaces of the annular ridge part
33 is set in accordance ;-/ith the gradient angle <|>.
[0059] FIG. 15 is a developed view of the outer
15 circumferential surface of the bottom roll 3 seen along
its circumferential direction. In FIG. 15, the x-axis
shows the rotation direction of the bottom roll 3. The
left end of FIG. 15 shows the start point of the bottom
roll 3, while the right end shows the end point of the
20 bottom roll. In the example which is shown in FIG. 15,
the transition part 33c is formed at about 60° to 120° and
the transition part 33d Is formed at about 240° to about
300°.
[0060] As will be understood from FIG. 15, in the
25- region 33a, the gradient angle is about 15°, the relief amount is made 1.3 mm or
so. In particular, in the present embodiment, the relief
angle is set in accordance with the absolute value of the
gradient angle <|>, and therefore in the region 33c where
5 the gradient angle (j) is 15° or so and the region 33d where
the gradient angle § is -15° or so, the relief amount x is
set to be substantially the same value.
[0061] Further, it is preferable to provide relief at
the side surfaces of the annular ridge part 33 of the
10 bottom roll 3 not only at the roll unit 20a of the final
station, but also part or all of the other roll units 20b
to 20k which are arranged upstream of it. The multistage
roll forming apparatus 2 which is shown in FIG. 2 bends
the top wall of the hat-shaped steel 1 in five steps from
15 the sixth station to the final station (10th station),
and therefore it is preferable to provide relief at the
bottom rolls 3 of these stations.
[0062] However, the top and bottom rolls 4 and 3 of
the stations differ in roll shape (in particular, the
20 inclination angle of the side walls of the annular ridge
part 33). Further, the minimum gap also changes according
to the inclination angle G of the side walls of the
annular ridge part 33 (the angle of the side walls of the
annular ridge part 33 with respect to the outer
25 circumferential surface of the annular ridge part 33 or
the outer circumferential surfaces of the flank parts 32,
or the angle with respect to the shaft direction of the
bottom roll 3). Specifically, the larger the inclination
angle 0, the larger the minimum gap. Therefore, the
30 inventors etc. engaged in actual designs and conducted
intensive studies and as a result discovered that the
preferable relief amount x becomes larger the larger the
inclination angle 0 of the side walls of the annular ridge
part 33. More specifically, they discovered that the
35 preferable relief amount x is proportional to the value
of the inclination angle G of the side walls of the
- 29 ~
annular ridge part 33 multiplied with the height H of the
annular ridge part 33 of the bottom roll 3 (x=pxHxtanO,
where [3 is a constant) . In this regard, the relief amount
x, the side wall angle 9 of the shaped steel, and the
5 height H of the annular ridge part 33 are as shown in
FIG. 16.
[0063] Further, the minimum gap varies depending on
the roll diameter R of the top and bottom rolls as well.
In this regard, the "roll diameter R" means the roll
10 diameter at the outer circumferential surface of the
annular ridge part 33 of the bottom roll 3 and the roll
diameter at the bottom surface of the annular groove part
42 of the top roll 4. Alternatively, the "roll diameter
R" may mean the roll diameter at the outer
15 circumferential surfaces of the flank parts 32 of the
bottom roll 3 and the roll diameter at the outer
circumferential surfaces of the flank parts 43 of the top
roll 4. Specifically, when the roll diameter R is
infinitely large, the phenomenon of the minimum gap
20 becoming smaller than the sheet thickness at the base
region of the annular ridge part 33 no longer arises.
Therefore, in the present embodiment, the larger the roll
diameter R, the smaller the relief amount x is set. In
particular, in the present embodiment, the relief amount
25 x is set to be inversely proportional to the roll
diameter R.
[0064] Summarizing the above, in the present
embodiment, the relief amount x is calculated by the
following formula (1).
30 x=axR7RxtanGx|tan|... (1)
were, a is a constant which is found by experiments or by
calculation.
[0065] In this way, in the present embodiment, by
setting the relief amount x in accordance with the
35 gradient angle <|>, inclination angle 0, and roll diameter R
which affect the minimum gap, it is possible to keep the
- 30 -
minimum gap from becoming smaller than the sheet
thickness. Further, if the relief amount x becomes too
large, the gap between the top and bottom rolls becomes
unnecessarily large and the sheet or strip M become
5 wrinkled or suitable bending can no longer be performed.
As opposed to this, in the present embodiment, the relief
amount x is set in accordance with the variation in the
gradient angle §, the inclination angle 9, and roll
diameter R in the longitudinal direction, and therefore
10 it is possible to set the relief amount x the smallest in
the range where the minimum gap does not become smaller
than the sheet thickness. For this reason, it is possible
to suppress wrinkling or unsuitable bending etc. of the
sheet or strip M.
15 [0066] Note that, in the above embodiment, the relief
amount x is set to the value which is calculated by the
above-mentioned formula (1). However, in actuality,
wrinkling etc. will not immediately be caused even if
increasing the relief amount somewhat compared with the
20 value which is calculated by the above-mentioned formula
(1). For this reason, the relief amount x may be said to
be at least the value which is calculated by the above
formula (1).
[0067] Further, the above-mentioned constant a can,
25 for example, be calculated as follows. FIG. 17 is a
partial vertical cross-sectional view of top and bottom
rolls 4 and 3 which are cut along the plane which
includes the center axes of the top and bottom rolls 4
and 3. In particular, FIG. 17 is a cross-sectional view
30 of the top and bottom rolls 4 and 3 at the transition
parts. In the example which is shown in FIG. 17, the gap
between the bottom roll 3 and the top roll 4 is basically
set to a predetermined value C, while the predetermined
value C is substantially the same as the sheet thickness
35 of the sheet or strip M which is bent between these top
and bottom rolls 4 and 3. On the other hand, when the
transition parts are provided in the above way, so long
- 31 -
as the side walls of the annular ridge part 33 are not
provided with relief, the gap between the side walls of
the top and bottom rolls 4 and 3 becomes smaller at the
transition parts. In the example shown in FIG. 17, relief
5 is not provided, and therefore the gap between the side
walls of the top and bottom rolls 4 and 3 becomes
partially smaller.
[0068] At this time, the minimum gap between the side
walls of the top and bottom rolls 4 and 3 is made Cmin.
10 Further, the gradient angle at the transition parts of
the top and bottom rolls 4 and 3 which are shown in FIG.
17 is made "i" and the inclination angle is made "9i". In
addition, the height of the annular ridge part 33 is made
"Hi" and the roll diameter is made "Ri". In this case, the
15 relief amount Xi which should be provided at the side
walls of the annular ridge part 33 is equal to C-Cmin,
and therefore the following formula (2) stands. As a
result, the constant a can be found as in the following
formula (3).
20 Xi=C-Cmin=axHi/RiXtan91x | tan^ [... (2)
a=C-Cmin/(H1/Rixtan9iX|tan<|>1| )...(3)
The constant a which is calculated in this way can be
used even if the roll diameter R, the inclination angle 0,
the gradient angle
FIG. 23A shows a hat-shaped steel 1 with a constant width
and height but with a cross-section which moves in the
- 36 -
lateral direction, while FIG. 23B shows the top and
bottom rolls 4 and 3 which form the hat-shaped steel 1 of
FIG. 23A by the final forming operation. That is, in the
above first embodiment, a hat-shaped steel with a
5 straight stock axis was produced, but in the present
embodiment, a hat-shaped steel 1 with a stock axis which
is curved in the width direction is produced. This hatshaped
steel 1 has portions 15a of a straight stock axis
and portions 15b of a curved stock axis. As the rolls for
10 this, as shown by the example in FIG. 23B, top and bottom
rolls 4 and 3 which have an annular ridge part and
annular groove part offset in the rotational axial
direction are used. The overall configuration of the roll
unit which drives rotation of the top and bottom rolls 4
15 and 3 can be configured in the same way as in the first
embodiment.
[0081] According to the present embodiment, by simple
control for making the top and bottom rolls rotate
synchronized, a hat-shaped steel with a cross-sectional
20 shape in the longitudinal direction which curves in the
width direction can be produced. Furthermore, if
arranging the roll units 20a to 20k in tandem curved in
the up-down direction, a hat-shaped steel which is curved
in the longitudinal direction can also be produced.
25 [0082]
FIG. 24A shows a hat-shaped steel 1 with a constant
height and a width in cross-sectional shape which varies
asymmetrically to the left and right, while FIG. 24B
shows the top and bottom rolls 4 and 3 which form the
30 final shape of the left-right asymmetric hat-shaped steel
1 which is shown in FIG. 24A. That is, in the present
embodiment, the top and bottom rolls 4 and 3 which are
shown in FIG. 23B are used to produce a hat-shaped steel
1 which has one side wall 10c of the hat shape which is
35 constant and has only the other side wall lOd changing in
the width direction. The overall structure of the roll
unit which drives rotation of the top and bottom rolls 4
- 37 -
and 3 can be configured in the same way as in the first
embodiment. In this case as well, by simple control for
making the top and bottom rolls 4 and 3 rotate
synchronized, a hat-shaped steel v/hich varies
5 asymmetrically left and right in cross-sectional shape
width in the longitudinal direction can be produced.
[0083]
15 The U-shaped steel 6 of FIGS. 27A and 22B is
substantially the same as the U-shaped steel 6 of FIGS.
26A and 21B except for being provided with the flanges
63. In this case as well, by simple control for making
the top and bottom rolls 4 and 3 rotate synchronized, a
20 U-shaped steel 6 which varies in cross-sectional shape
width in the longitudinal direction can be produced.
[0086]
The present embodiment also produces shaped steel having
a U-shape cross-section. However, while the above-
25 mentioned fifth embodiment has a constant height, in the
present embodiment, as shown in FIG. 28A, a U-shaped
steel 6 with a constant width and a changing height is
produced. More specifically, the U-shaped steel 6 of the
present embodiment has a heightening portion 61c with a
30 constant width and a lowering portion 61d with a constant
width. FIG. 28B shows the top and bottom rolls 4 and 3 of
the final station for the U-shaped steel 6 which is shovm
in FIG. 28A. The annular ridge part of the bottom roll 3
has a cross-sectional outer shape of an inverted U-shape,
35 expands in outside diameter in the circumferential
direction in the range of 0° to 180°, and contracts in
- 39 -
outside diameter in the range of 180° to 360°. The
recessed part of the top roll 4 which faces the bottom
roll 3 also has a U-shape which varies in height in the
circumferential direction. The overall structure of the
5 roll unit which drives rotation of the top and bottom
rolls 4 and 3 can be configured in the same way as in the
first embodiment. In this case as well, by simple control
for making the top and bottom rolls 4 and 3 rotate
synchronized, a U-shaped steel 6 which varies in cross-
10 sectional shape height in the longitudinal direction can
be produced.
[0087]
Except for the point of the U-shaped steel 6 of FIGS. 2 9A
and 24B being provided with the flanges 63, this is
15 substantially the same as the U-shaped steel 6 of FIGS.
27A and 22B. In this case as well, by simple control for
making the top and bottom rolls 4 and 3 rotate
synchronized, a U-shaped steel 6 which varies in crosssectional
shape width in the longitudinal direction can
20 be produced.
[0088] <10th Embodiment
The present embodiment produces a shaped steel which
forms a cross-sectional V-shape. FIG. 30A shows a Vshaped
steel 7 with a width in cross-sectional shape
25 which is constant and a height which varies, while FIG.
30B shows the top and bottom rolls 4 and 3 of the final
station for the V-shaped steel 7 which is shown in FIG.
30A. More specifically, the V-shaped steel 7 of the
present embodiment has a heightening portion 71a with a
30 constant width and a lowering portion 71b with a constant
width. The annular ridge part of the bottom roll 3 has a
cross-sectional outer shape of a triangular shape (Vshape)
and an expanding outside diameter in the
circumferential direction in the range of 0° to 180° and
35 decreasing outside diameter in the range of 180° to 360°.
The recessed part of the top roll 4 which faces the
- 40 -
bottom roll 3 also becomes a triangular shape (V-shape)
which varies in height in the circumferential direction.
The roll unit which drives rotation of the top and bottom
rolls 4 and 3 can be configured in overall structure in
5 the same way as in the first embodiment. In this case as
well, by simple control for making the top and bottom
rolls 4 and 3 rotate synchronized, a V-shaped steel 7
which varies in height in cross-sectional shape in the
longitudinal direction can be produced.
10 [0089]
FIG. 31A shows a hat-shaped steel 1 which varies in both
width and height of cross-sectional shape, while FIG. 3IB
shows the top and bottom rolls 4 and 3 of the final
station for the shape of the hat-shaped steel 1 which is
15 shown in FIG. 31A. More specifically, the hat-shaped
steel 1 of the present embodiment has a portion 17a of a
cross-sectional shape width Ll and height hi, a portion
17b of a cross-sectional shape width L2 and height h2,
and a portion 17c of a changing width Ll to L2 and height
20 hi to h2. For this reason, the annular ridge part and
annular groove part of the top and bottom rolls 4 and 3
are made shapes which vary in both height and width of
cross-sectional shape in the circumferential direction
(L1^-L2^L1, hl^-h2^-hl) . The overall structure of the roll
25 unit which drives rotation of the top and bottom rolls 4
and 3 can be configured in the same way as in the first
embodiment. In this case as well, by simple control for
making the top and bottom rolls 4 and 3 rotate
synchronized, a hat-shaped steel 1 which varies in both
30 width and height in cross-sectional shape can be
produced.
[0090] Above, the present invention was explained In
detail with reference to specific embodiments, but
various substitutions, alterations, changes, etc.
35 relating to the format or details are possible without
departing from the spirit and scope of the invention such
as defined by the language in the claims will be clear to
- 41 -
a person having ordinary skill in the technical field.
Therefore, the scope of the present invention is not
limited to the above-mentioned embodiment and attached
figures and should be determined based on the description
5 of the claims and equivalents to the same.
Reference Notations List
[0091] 1 hat-shaped steel
2 multistage roll forming apparatus
3 bottom roll
10 32 flank part
33 annular ridge part
4 top roll
42 annular groove part
43 flank part
CLAIMS
Claim 1. A method of producing a shaped steel which
varies in cross-sectional shape in the longitudinal
direction from a sheet by roll forming, comprising:
5 a step of preparing a first rolling die which
has a rotation shaft and an annular ridge part which
varies in cross-sectional shape in a circumferential
direction which is centered about said rotation shaft;
a step of arranging said first rolling die so
10 that the rotation shaft of said first rolling die becomes
perpendicular to a sheet feed direction;
a step of preparing a second rolling die which
has a rotation shaft and an annular groove part which
varies in cross-sectional shape in a circumferential
15 direction which is centered about said rotation shaft;
a step of arranging said second rolling die so
that a gap which is equal to a thickness of said sheet is
formed between said first rolling die and second rolling
die and the annular ridge part of said first rolling die
20 and the annular groove part of said second rolling die
engage;
a step of making said first rolling die and
said second rolling die rotate synchronized; and
a step of feeding a sheet between said first
25 rolling die and second rolling die,
wherein the side surfaces of the annular ridge
part of said first rolling die are provided with relief
so that the gap with respect to side surfaces of the
annular groove part of the second rolling die broadens
30 over at least part of the circumferential direction and
at an 'inner side in the radial direction of said first
rolling die,
wherein said annular ridge part of said first
rolling die is configured so that the relative angle
35 between the ridgeline and the rotation direction of said
first rolling die varies at least partially in the
circumferential direction, and
- 43 -
wherein the relief amount at said relief is set
to vary in accordance with the relative angle betv/een the
ridgeline of the annular ridge part of said first rolling
die and the rotation direction of said first rolling die.
5 Claim 2. The method of production of a shaped steel
according to claim 1 characterized in that the larger
said relative angle, the larger said relief amount is
made.
Claim 3. The method of production of a shaped steel
10 according to claim 1 or 2 characterized in that said
annular ridge part of said first rolling die is
configured so that a height dimension which is measured
in a perpendicular direction with respect to said
rotation shaft varies at least partially in the
15 circumferential direction, and in that said relief amount
is made larger the higher the height of said annular
ridge part.
Claim 4. The method of production of a shaped steel
according to any one of claims 1 to 3 characterized in
20 that said shaped steel is a hat-shaped steel with an
inner circumferential surface which is rolled by the
annular ridge part of said first rolling die and with an
outer circumferential surface which is rolled by the
annular groove part of the second rolling die.
25 Claim 5. The method of production of a shaped steel
according to any one of claims 1 to 4 characterized in
that the annular ridge part of said first rolling die
includes, in its circumferential direction, a first roll
width region, a second roll width region, and a tapered
30 region which increases or decreases in width from said
first -roll width to second roll width.
Claim 6. The method of production of a shaped steel
according to any one of claims 1 to 4 characterized in
that said first rolling die has an annular ridge part
35 which is offset in the rotation shaft direction in its
circumferential direction and produces a shaped steel
having stock axis which is curved in the width direction.
~ 44 -
Claim 7. The method of production of a shaped steel
according to claim 1 characterized in that the relief
amount x of the side surfaces of said first rolling die
is set to not less than a value x1 which is calculated by
5 the following formula (1):
x'=ctxH/RxtanGx|tan", and a is a constant.
Claim 8. The method of production of a shaped steel
according to claim 7 characterized in that a plurality of
roll units each of which comprises first rolling dies and
15 second rolling dies are arranged in series in a sheet
feed direction and the material is bent by these
plurality of roll units so that the side wall angle 6 is
increased in stages, and in that the relief amount x of
the side surfaces of the first rolling die of part or all
20 of the roll units is not less than a value which is
calculated by the formula (1).
Claim 9. The method of production of a shaped steel
according to any one of claims 1 to 8 characterized in
that the relief which is provided at the side surfaces of
25 the annular ridge part of said first rolling die is
started separated from the ridgeline of said annular
ridge part by a predetermined length L and said
predetermined length L is set so that, when the height of
said annular ridge part is "H", 0", and a is a- constant.