Center shifted roll forming

Abstract

The present invention provides a bending machine for strip, webbing, or rod material comprising: an electronic control means; two cylinders, each acting selectively as a forming mandrel or a forming tool; an angular displacement means, controlling the orbit of the forming mandrel; and a feeding means, controlling the rate of material advancement; wherein a curvilinear profile of varying radii is formed in at least a portion of a material by varying the feed rate and the angular displacement, individually or in conjunction.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This is a continuation-in-part of application Ser. No. 10 / 896,257, filed Jul. 21, 2004, now abandoned.BACKGROUND OF THE INVENTION [0002] This invention relates generally to an improved roll forming mechanism. And, more particularly, this invention relates to the forming of malleable materials, such as tubes, strips, sheets, webbing, and similar materials into a curvilinear profile, using a roll form machine known to industry, wherein two parallel cylinders selectively act as both a forming mandrel and a forming tool. [0003] As designs in numerous industries become more organic and irregular, having non-repeating patterns and complex shapes (designed to increase strength, increase beauty, maximize performance, or provide clearance), devices are required to form these complex shapes and underlying frameworks. Industries employing these complex design profiles include the aerospace, construction, process industries, and many others. [0004]...

AI Technical Summary

Benefits of technology

[0008] In accordance of the present invention, a roll forming machine capable of quickly and economically producing complex curvilinear patterns in malleable materials is provided. The present invention further provides a device that can produce a bending radius that is approximately equal to or greater than the forming mandrel. The present invention again further provides a device that can be programmed to bend a complex series of radii or planar sections along a material.

[0015] The present invention can form complex curvilinear profiles in materials by adjusting the feed rate of the material and the angular displacement of the forming tool. For example, if a formed radius that is larger than the forming mandrel is required, the angular displacement can be held constant while the material is advanced. Or, if a complex curve (second, third, or nth order equation) is required, the feed rate and the angular displacement can be adjusted simultaneously. For a small radius with a sharp bend angle, it may be necessary to slow the feed rate while increasing the angular displacement. Along the length of the material, the radius and bend angle can be varied, the present invention transitioning easily from one portion of a complex curve to another. Many complex shapes are possible with the present invention, through controlled variations in material feed rate and angular displacement.

[0026] In the case of the manufacture of a titanium webbing for application in aerospace, the design of the webbing is created, taking into account the strength requirements of the structural member and interferences with nearby structures and components. The final webbing design, in this exemplified case, is a complex series of curves of varying radii and planar sections, forming a curvilinear profile. This complex curvilinear profile can be created accurately by the roll form device of the present invention.

Problems solved by technology

These devices are limited in the shapes that can be produced.

More complex shapes required in modern industry are not possible with current roll forming means

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

Images