Continuous process of roll-forming pre-stamped varying shapes

Abstract

An apparatus includes a press with dies configured to deform a strip of material by drawing material primarily from a width direction, a slitter set to cut the deformed strip to a uniform desired width dimension, and a roll-former with rolls configured to shape linear portions of the deformed and now uniform-width strip into a continuous beam. The apparatus further includes a welder for welding abutting edges of the sheet together to form a permanent tube, a sweep station for imparting a longitudinal shape to the continuous beam, and a cut-off for cutting the continuous beam into segments useful as vehicle bumper beams. A controller controls timing of various components. The beam segments are optimized in specific regions for local strength and minimized weight, and features can be incorporated into the beam segments such as coplanar mounting surfaces.

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims benefit of provisional application Ser. No. 60 / 723,393, filed Oct. 4, 2005, entitled CONTINUOUS PROCESS OF ROLL-FORMING PRE-STAMPED VARYING SHAPESBACKGROUND [0002] The present invention relates to a continuous process of roll-forming pre-stamped varying shapes, and more particularly relates to a process combining a stamping / deforming process with a roll-forming apparatus to obtain advantages of both in a continuous process. [0003] The advantages associated with roll-forming have made roll-forming a preferred manufacturing method for many open structural sections and tubular structural sections. [0004] Automotive bumpers beams are one example of a product that has capitalized on the benefits of roll-forming to produce light weight, low cost, and performance based designs that are widely accepted and used commercially. Roll-formed tubular bumper beams represent a majority of the bumper beam market and continue to g...

AI Technical Summary

Benefits of technology

The present invention is about an apparatus and method for making reinforcement beams. The apparatus includes a press with dies to deform a flat strip of material into a deformed strip with a three-dimensional shape, a slitter to cut the deformed strip to a uniform width, and a roll-former to shape linear portions of the deformed and uniform-width strip into a continuous beam. The method involves providing a single elongated sheet with three strip portions integrally connected together, stamping the first strip portion to deform it, and roll-forming the second and third strip portions. The resulting reinforcement beam has optimized local beam strength and minimized weight and wasted material. The concepts can also be applied to open sections.

Problems solved by technology

Some limitations of roll-forming include the inability to change material properties within the part and the inability to change the cross section along the length of the part.

The inability to change the cross section along the length of the part typically results in excessive material being used in areas where it is not needed to meet performance requirements in other areas where it is needed.

The excessive material also adds to the weight of the part and to material cost.

The inability to change the cross section of a roll-formed tubular beam along its length results in a tubular beam with a constant moment of inertia.

However, stamping operations are limited and generally less efficient than roll-forming since individual sheet blanks must be laterally moved and accurately positioned after each die stroke.

Also, dies cannot make tubular beams.

Further, UHSS sheet material is very wearing on dies depending on the amount of shape deformation being imparted onto the sheet material and depending on a strength of the material.

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