RU2286860C2 - Device for making thin-walled sections by forming flat blanks to shaft - Google Patents

Abstract

FIELD: plastic metal working.

SUBSTANCE: invention can be used in manufacture of thin-walled sections from sheet blanks by forming in rolls. Device contains shaping stands installed in process sequence and coupled with common drive. Each stand has two shafts with shaping rolls. Unit of feed rollers with blank cutting knife and clearance is installed before first shaping stand. Shaping rolls of all stands are paired for simultaneous shaping of two blanks. First and second stands are combined into unit being arranged in one housing. roll, for forming to shape of one blank of lower paired roll of first stand, is made of metal and provided with knurling. Roll for forming to shape of one blank of upper paired roll of first stand is also made of metal and is provided with cylindrical form part on section forming wall of future section smoothly changing into conical part on section forming bent down webs of section and is lined with elastic material over length. Shafts for mounting shaping rolls in all stands are made in form of inserts installed for demounting of rolls when disassembling the stands.

EFFECT: enlarged operating capabilities, improved quality of section and increased output.

3 cl, 1 ex, 5 dwg

Description

The invention relates to the field of metal forming and can be used, in particular, in the manufacture of thin-walled profiles from sheet blanks by roll profiling for aerospace products and the construction industry. The invention is aimed at expanding technological capabilities, improving productivity and quality of bent from a sheet of profiles.

It is known "Device for the manufacture of profiles" (see IPC patent ⁷ B 21 D 5/06 No. 2148455, publ. BI No. 13, 05/10/2000), according to which profiles from sheet blanks are made in alternating forming and pulling working stands, each of which are included in one common kinematic chain associated with the drive. The working stand has two shafts located one above the other, on which roll forming rolls (rollers) are rigidly fixed. The upper shaft of each stand is located at the ends in slide sleeves having the ability to move vertically along the guide cheeks of the stand body.

The device has the following disadvantages:

the complexity of the kinematic chain, consisting of a system of gears, including with additional external gearing, which increases power loss and reduces the efficiency of the device;

there is no certainty in eliminating the waviness along the edges of the bent sections of a thin workpiece (S ₀ ≤1.0 mm), which does not guarantee the quality of the profiles.

Also known is the device presented in RF patent No. 2236319 "Method for profiling thin-walled profiles and a device for its implementation", publ. 09/20/2004, Bull. No. 26, adopted as a prototype, which contains a number of cross-profiling stands installed in a technological sequence, connected by a single kinematic chain with a common drive, each profiling stand has two shafts located one above the other, with profiling rolls mounted on them, the ends of the upper profiling rolls are placed in slide sleeves having the ability to move vertically along the guide walls of the housing; the profiling rolls of the first stand are cylindrical, with the lower roll made of metal with corrugations in the form of protrusions of a triangular rounded section with a height h≤ (3 ... 5) S ₀ at a constant step, where S ₀ is the initial thickness of the workpiece, which alternate with smooth segmented surfaces, and the upper profiling roll is made of metal, cylindrical in the section of the future profile wall, smoothly turning into a conical shape in the section of the foldable shelves, and is lined with elastic material along the entire length, the thickness is orogo at least the cylindrical portion and is increased at the ends.

The prototype and the claimed invention have the following similar essential features:

contain a number of stands milling for transitions installed in the technological sequence;

profiling stands are connected by a single kinematic chain with a common drive;

each profiling stand has two shafts located one above the other, with profiling rolls mounted on them;

the ends of the upper profiling rolls are placed in slide sleeves having the ability to move vertically along the guide walls of the casing.

These signs are necessary to ensure a technical result.

The known device has the following disadvantages:

it is not clear how the workpiece is fed into the first profiling stand;

excessive metal consumption with a significant narrowing of the width of the profiled workpiece, if all stands will have the same width;

poor performance.

The technical result is the expansion of technological capabilities, increasing productivity and quality profiles.

According to the first claim, a device is a series of profiling stands located in housings;

in front of the first profiling stand, a block of feed rollers (rolls) with a knife for cutting the workpiece and a tool in the form of a thin grinding wheel for cleaning the ends of the workpiece along the cutting line are installed;

profiling rolls of the first profiling stand and all subsequent ones are made paired with the possibility of simultaneous profiling of two workpieces, which increases the productivity of the unit;

the first and second profiling stands are made in one housing with a connector along the axis of the upper profiling roll, which simplifies the adjustment of the unit when changing the profiling rolls;

profiling rolls installed in the housing on the shafts, allowing their dismantling during replacement;

in a separate housing there is a block of feed rollers with a knife for cutting the workpiece and means for stripping;

the last profiling stand is calibrated with a closed working caliber, has an increased rotation speed to create additional tensile forces.

The most simple design of the proposed device will be in the manufacture of channel profiles

Between the distinctive features of the claimed invention and the technical result there is the following causal relationship:

the creation of transverse corrugations on a workpiece cut into two parts provides the necessary supply of material, on the rolling of which in the profiling direction part of the material compensates for the unevenness of deformations along the width of the foldable shelves and the wall, and part of the material "flows" into the corner zones, which increases the rigidity of the profile, eliminates the edge waviness , which means it improves the quality of manufactured profiles;

lining of the upper roll with an elastic material, its various thicknesses make distributed deforming forces of various sizes along the workpiece width, due to which the corrugations get variable in cross-sectional shape and depth, which also extends technological capabilities and improves the quality of profiles;

the use of the feed roller block ensures the supply of the profiled workpiece into the forming unit with two streams, which increases productivity, micro-grinding for deburring improves the quality of the profiles;

dividing the device into three blocks expands technological capabilities, allows you to adjust the process depending on the thickness and material of the workpiece.

The set of essential features characterizing the essence of the invention can be repeatedly used in roll forming machines and mills, drawing and rolling plants in the manufacture of sheet-walled thin-walled wide-shelf profiles in mechanical engineering, the construction industry and the aerospace industry for a wide range of materials, including difficult to deform, in conditions cold deformation, which allows us to conclude that the invention meets the criterion of "industrial applicability".

Some distinctive features of the proposed technical solution are more or less known in the literature.

According to the information available to the authors, the set of essential features characterizing the essence of the claimed invention is not known from the prior art, which allows us to conclude that the invention meets the criterion of "novelty."

According to the authors, the essence of the claimed invention does not follow explicitly from the prior art for a specialist, since the above effect on the technical result is not revealed from it - a new property of the object: a set of features that distinguish the claimed invention from the prototype, which makes it possible to conclude its compliance with the criterion of "inventive step".

The invention is illustrated graphic materials. Figure 1 presents the profiling scheme (top view) with the creation of transverse corrugations and the composition of the device; figure 2 is a section aa in figure 1; figure 3 - section bB in figure 1 - structural elements of the roll pair of the first transition; figure 4 - section bb in figure 1 - structural elements of the roll pair of the calibrating transition; 5 is a diagram of the supply and cutting of the workpiece.

The device provides the following profiling process.

A flat workpiece 1 with a thickness of S ₀ ≤1.0 ... 2.0 mm is captured by the rotating rolls of the feeding unit 2, the rolls of which have a knife 3 for cutting the workpiece and means 4 for deburring along the cut line of the workpiece (Fig. 1). Then the flat workpiece enters the first profiling stand 5 with two streams 6, where transverse corrugations (corrugations) 7 of variable cross-sectional shape with a constant pitch t = (10 ... 20) S ₀ (FIG. 2) are rolled across them over the entire width decreasing gradually from h = h _max = const along the width of the future profile wall to h = 0 along both edges of the bent sections of the workpiece. At the same time, the blanks in the places where corrugations are formed have practically no thinning, since the rotating rolls 8, 9 (FIGS. 2, 3) of the forming stand 5 are installed along the axial vertical plane with some clearance and the blank 1 is freely drawn into it.

Profile stands 5, 10, 11, 12, etc. (driven and non-driven) are installed in the technological sequence, include rolls 8, 9, etc. with profiled work surface. The last calibrating stand 12 has an increased speed of rotation of the shafts 13, 14, ensures the displacement of the rolled corrugation material in the profiling direction, which eliminates the waviness of the edges of the obtained profiles 15, 16. Gradual bending of the profile 17 can be carried out in each previous stand.

The roll pair of the profiling stand 5 over the entire width of the lower roll 9 has corrugations (knurling) of a triangular rounded shape in the form of protrusions 18 (Fig.2). Corrugation height h = h _max ≤ (3.0 ... 5.0) S ₀ depending on the geometric characteristics of the cross section of the bent elements and the mechanical properties of the profiled workpiece. The corrugation pitch is constant. The protrusions alternate with smooth segmented surfaces with a step t = (10 ... 20) S ₀ in order to ensure the required excess of metal to eliminate the profile waviness along the edges. The lower roll 9 is a completely metal, cylindrical shape (figure 3) has a slot separating the two parts of the profiled workpiece. The upper roll 8 is made of metal in the cylindrical part in the area of the future profile wall, smoothly turning into a conical shape 19 in the area of the foldable shelves. The roll has a lining with elastic material 20 (FIGS. 2, 3) of the smallest thickness on the section of the future profile wall and the largest for the shoulders 21, which limit the width of the profiled parts of the workpiece 1. The thickness of the elastic part (cladding) depends on the metal grade of the profiled workpiece, its thickness and elastic cladding material properties.

The rolls are mounted on shafts 22, 23 with a keyway 24 along the entire length of the sliding bearings 25. To adjust the workpiece thickness S _{0, the} upper roll 8 of each profiling stand together with the shaft 22, the ends of which are enclosed in slide sleeves 26, can be moved vertically along the guide walls 27 of the housing of the stands (figure 3, 4).

According to the second claim, the device is provided with a separate housing for accommodating the block of feed rollers with a knife for cutting the workpiece and means for stripping.

The supply unit 2 (Fig. 1) consists of rotating rollers 28 and 29 (Fig. 5), which can be adjusted to the thickness of the profiled workpiece 1, mounted on shafts located in the bearings of the housing 30, and the knife 3. On the housing behind the knife 3 is placed means 4 in the form of a thin grinding wheel for deburring the cut workpiece. Profile rolls 8, 9, 13, 14, etc. made with the possibility of profiling simultaneously two blanks. The first and second profiling stands are made in one housing 31 with a connector along the axis 32 of the upper rolls of stands 5, 10. The last profiling stand 12 (Fig. 1) is calibrated with two closed working calibers (Fig. 4) to obtain profiles 15, 16.

According to the third claim, the block body of the first and second profiling stands 5, 10 is cast, stepped in plan with a connector along the axes 32 for assembly and disassembly when replacing the profiling roller pairs. The installation of the rolls on the shafts 26 with a center distance A provides for dismantling during parsing. The stepped shape is associated with a decrease in the width of the profiling rolls.

The device operates as follows. The rotation from the common drive through the transmission system is transmitted to the shafts of the profiling stands (Fig. 1). A flat workpiece 1 in the form of a roll tape is captured by drive rolls 28, 29 of the feeding unit 2, where the knife 3 cuts it into two parts, the tool 4 removes burrs along the cutting line, after which the workpiece feeds into the forming stand 5 with drive rolls 8, 9 with two tapes . The roller 8 squeezes thin preform 18 around the lower corrugation roll 9. Due to its cylindrical surface 20 of the elastic variable stiffness both sides of the workpiece have corrugations h = h _max (on the centreline of the rolls) at the site of the future profile wall, is reduced to h = 0 on the edges, where the lowest rigidity of the elastic lining. Then the corrugated billet is fed into a drive roll pair 10, the rolls of which have a smooth working surface, provide in closed working calibers a partial bending of tapes on sections of future shelves and rolling corrugations (corrugation). According to the shaping scheme, both tapes 17 can subsequently be profiled in two or three stands like 11 (driven or non-driven) and fed to a calibrating stand 12, which, due to the increased speed of rotation of the rolls 13, 14, creates an additional tensile force, which ensures equalization of deformations and stresses the entire cross section of the resulting profiles 15, 16.

Example. On bending and rolling machines of the GPS-300M model, drawing and rolling installation of the VPU-120 / 7.5 model, the proposed technical solutions were worked out when profiling workpieces S ₀ = 0.5 and 0.8 mm; 1.0 and 1.5 mm from sheet blanks of alloys D16AM, D16AT, OT4-1 of various steels in the manufacture of rolls with corrugations of 2.0 and 4.0 mm. For facing the upper rolls of the first pairs used polyurethane brand SKU-7L and SP-7. Corrugation pitch through 20S ₀ . The gap in the rolls of the first pair in the non-grooved sections Z to 0.5S ₀ . Metal thinning in the corrugation zone did not exceed 1.5 ... 2.5%. It was possible to eliminate the edge waviness in all cases of channel profiling by the dimensions of the wall and shelves 50 × 50 mm.

The claimed invention is of interest to the national economy, because it allows you to profile in the cold state sheet blanks with a thickness of up to 2.0 mm from a wide range of metals with an accuracy of profile parameters corresponding to 10-14 conditions. The combination of rolling and drawing processes eliminates not only the waviness of the edges, but also reduces springing, improves surface quality, and makes the metal structure fine-grained.

The claimed technical solution does not adversely affect the state of the environment.

Claims (3)

1. A device for manufacturing thin-walled profiles by profiling flat blanks, containing a number of profiling stands located in the housings, installed in a technological sequence and connected by a single kinematic chain with a common drive, each profiling stand has two shafts located one above the other with profiling rolls mounted on them, and the ends of the upper profiling rolls are placed in slide sleeves having the ability to move vertically along the guides located on the walls to casing stands, characterized in that it is provided with a feed roller unit with a knife for cutting the workpiece installed in front of the first profiling stand and a means for cleaning along the cut line of the workpieces obtained by cutting, the profiling rolls of all profiling stands are paired for simultaneously profiling the two workpieces and the second profiling stands are combined in a block located in one housing, a roll for profiling one blank of the lower paired roll of the first profiling stand made of metal and with corrugations arranged with a constant pitch in the form of protrusions alternating with smooth segmented surfaces, having a triangular cross-section with rounding and a height h≤ (3-5) S ₀ , where S ₀ is the initial thickness of a flat workpiece, a roll for profiling one workpiece of the upper paired roll of the said first profiling stand is made of metal, has a part of a cylindrical shape at the formation site of the future profile wall, smoothly turning into a conical shape in the areas of formation of bendable the profile lock, and is lined along the entire length with elastic material having the smallest thickness on the cylindrical part, increased at the ends, while the housing of the first and second profiling stands is made with a connector along the axis of the upper profiling roll, and the shafts for installing profiling rolls in all profiling stands made in the form of inserts installed in the housing with the ability to dismantle the rolls during parsing. 2. The device according to claim 1, characterized in that it is equipped with a separate housing for accommodating the block of feed rollers with a knife for cutting the workpiece and means for stripping, and the last profiling stand during the technological process is designed to calibrate the profile and is made with a closed working caliber and with the possibility of rotation with increased speed to create additional tensile forces. 3. The device according to claim 1, characterized in that the casing of the block of the first and second profiling stands is made in terms of a stepped shape and obtained by casting.

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