Center shifted roll forming

Abstract

A roll forming machine capable of forming the corrugated metal web of a sinusoidal structural member is provided. The preferred embodiment includes a material feeding means, a material guiding means, and at least two forming cylinders. The material feeding means receives a sheet of material, and is in material communication with the material guiding means. The material guiding means receives the sheet of material, guiding the sheet of material into the forming cylinders and preventing significant movement or buckling of the sheet of material. The forming cylinders are a set of at least two substantially aligned and parallel cylinders, having a separation between sufficient to receive the sheet of material. The forming cylinders can alternately orbit one around the other, one forming cylinder axis being held substantially stationary while the other forming cylinder orbits the stationary cylinder, bending the sheet of material and forming the desired web geometry.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is entitled to the benefit of Provisional Patent Application Ser. No. 60 / 488,663 filed on Jul. 21, 2003.BACKGROUND [0002] 1. Field of Invention [0003] This invention relates generally to an improved roll forming mechanism. And, more particularly, this invention relates to an improved roll forming mechanism for the manufacture of the corrugated webbing of structural members for the aerospace industry. [0004] 2. Description of Prior Art [0005] In the aircraft industry, it is common to utilize I-beam like structural members having a sinusoidal web extending normally between a top and bottom flange. The generally sinusoidal shape of the web provides increased strength to weight performance, improved stiffness, and decreased volume. In order to accommodate the aircraft wiring harness, hydraulic and fuel lines, as well as immediate strength and volume requirements, the geometry of the web may vary from sinusoidal to planar, c...

AI Technical Summary

Benefits of technology

[0010] In accordance of the present invention, a roll forming machine capable of forming the corrugated metal web of a sinusoidal structural member is provided. The preferred embodiment includes a material feeding means, a material guiding means, and at least two forming cylinders. The material feeding means receives a sheet of material, and is in material communication with the material guiding means. The material guiding means receives the sheet of material, guiding the sheet of material into the forming cylinders and preventing significant movement or buckling of the sheet of material. The forming cylinders are an assembly of at least two substantially aligned and parallel cylinders, having a separation between sufficient to receive the sheet of material. The forming cylinders can alternately orbit one around the other, one forming cylinder axis being held substantially stationary while the other forming cylinder orbits the stationary cylinder, bending the sheet of material and forming the desired web geometry.

[0013] During the forming of the metal web, the sinusoidal pattern of the web can be altered, creating various curves or planar sections. To produce a planar section, the sheet of material is advance while the forming cylinders are both in the home position. The length of the advancement corresponds to the designed planar section length. Additionally, various curves can be produced by reducing or increasing the angle of travel of the orbiting forming cylinder, effectively changing the sector of the arc.

Problems solved by technology

With either choice of material, the construction of a structural member with a sinusoidal web is a challenge, in maintaining quality, tolerances, and minimizing costs.

Certain materials, such as titanium alloy 6-4, have considerable spring-back properties, making them relatively difficult to roll form to the tight tolerances required in the aerospace industry.

This method lends itself to very rapid production however it is not adjustable to accommotade for slight variations in metal spring back nor is it capable of producing variations in shape.

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