A profile roll forming processing method and a processed profile

Abstract

This invention discloses a method for roll forming of profiles and the profiles processed therefrom. The method includes the following steps: 1) Installing a bending die; 2) Pressing the workpiece firmly onto the upper surface of the bending die, with the end to be folded extending beyond the worktable surface; 3) Moving the cantilever end of the Y-axis, which moves along the X, Y, and Z axes, to a position corresponding to the workpiece, and pressing the roller against the end of the workpiece by a rotating motor; 4) Driving the roller to move along the X-axis, bending the workpiece at a certain angle; 5) After the roller advances, it moves again along the X-axis to bend the workpiece to a larger angle, and this process is repeated until the workpiece reaches the preset bending angle. This device achieves bending processing through multiple roll forming processes. It has low overall motor power, low processing energy consumption, small device size, and a wider range of applications. It can process automotive parts, door and window frames, highway guardrails, and other components.

Description

Technical Field

[0001] This invention relates to a method for producing profiles, and more particularly to a method for roll forming of profiles and the resulting profiles. Background Technology

[0002] In the prior art, a bending machine is often used for bending profiles. This bending machine includes a worktable and a sliding block device that moves up and down. A lower die is set on the worktable, and an upper die is set at the lower end of the sliding block device. The upper and lower dies match each other to form a bending profile. The workpiece to be processed is placed between the upper and lower dies. The sliding block moves down, causing the upper and lower dies to close, and the workpiece is forced to be squeezed into a certain angle. This device processes the workpiece into shape in one go, with fast production speed and high production efficiency.

[0003] Its shortcomings are: during the extrusion process, due to the high stamping speed, the internal stress of the workpiece cannot be released in time, which limits the processed products. It cannot process workpieces with relatively high brittleness and is prone to small cracks inside the workpiece, affecting its strength. In addition, existing bending machines have high power and high energy consumption during operation, and also exert a large impact on the machine tool. Therefore, the support structure of the machine tool is also very bulky. Summary of the Invention

[0004] The purpose of this invention is to provide a profile roll forming method that releases the internal stress of the profile in a timely manner during the processing, enabling the processing of brittle workpieces, with low processing energy consumption, small device size, and wide range of applications.

[0005] The objective of this invention is achieved as follows: a method for roll forming of profiles, comprising the following steps:

[0006] 1) A bending die is installed on the edge of the workbench, the bending die comprising at least two working surfaces arranged at an angle.

[0007] 2) Press the workpiece firmly onto the upper surface of the bending die so that the end to be bent protrudes from the worktable surface.

[0008] 3) Move the Y-axis cantilever end, which moves along the X, Y and Z axes, to a position corresponding to the workpiece. The Y-axis cantilever end is equipped with a flip motor. The axis of the flip motor is parallel to the X-axis. The output shaft of the flip motor is connected to the flip bracket. The flip bracket is equipped with a roller shaft. The roller shaft is equipped with a pressure roller. The axis of the pressure roller is spatially perpendicular to the axis of the flip motor. The pressure roller presses against the end of the workpiece.

[0009] 4) The flipping motor first bends the end of the workpiece at a certain angle, and then drives the roller to move along the X-axis. The roller presses against the surface of the workpiece, so that the entire workpiece is bent at a certain angle.

[0010] 5) The flipping motor rotates again at a certain angle, and at the same time moves in the Z-axis and Y-axis directions to ensure that the roller is always pressed against the surface of the workpiece. The roller moves again along the X-axis to bend the workpiece to a larger angle. This process is repeated until the workpiece reaches the preset bending angle.

[0011] Furthermore, when the roller advances, it reciprocates in the X-axis direction.

[0012] To eliminate workpiece springback, the final bending angle of the rollers is 1-5° larger than the preset bending angle.

[0013] A further improvement is that a crossbeam is provided above the side of the worktable, and a connecting bracket is mounted on the crossbeam via an X-axis guide rail slider mechanism. An X-axis drive motor is provided on the connecting bracket to drive the connecting bracket to move along the X-axis. A Z-axis cantilever is connected to the connecting bracket via a Z-axis guide rail slider mechanism, and a Z-axis drive motor is also provided on the connecting bracket to drive the Z-axis cantilever to move along the Z-axis. A Y-axis cantilever is connected to the lower end of the Z-axis cantilever via a Y-axis guide rail slider mechanism, and a Y-axis drive motor is provided at the lower end of the Z-axis cantilever to drive the Y-axis cantilever to move along the Y-axis.

[0014] Furthermore, a pressure plate is provided above the worktable for pressing and fixing the workpiece on the upper side of the bending die. The pressure plate is located at the lower end of the piston rod of the hydraulic cylinder, the hydraulic cylinder is fixed on the bed, and a pad is provided on the lower side of the pressure plate.

[0015] Furthermore, the bending die is fixed to the corner of the workbench by screws.

[0016] Under the operation of the roller press motor, the roller press is driven to rotate by the roller press motor. Its active rotation is consistent with the X-axis, so that the surface of the workpiece is not easily scratched during the forming process.

[0017] To improve the stability and machining accuracy of the device, the crossbeam is mounted on the machine bed via a mounting section. This structure ensures that the crossbeam and the worktable are relatively fixed in position, thereby improving machining accuracy.

[0018] A further improvement is that the bending die is composed of multiple unit modules spliced ​​together along its length. These unit modules are easy to process, versatile, and easy to replace and install. The unit modules can also have different profiles; for example, the bending die may have one part with two working surfaces and another part with three working surfaces. The workpiece can be partially bent at one angle, while the remaining part can be bent at another angle. Alternatively, after partial bending, further bending can be performed at the folded edge to form a partial zigzag bend.

[0019] Compared with existing technologies, the advantages of this invention are as follows: The device allows for free adjustment of the bending angle for each stroke, resulting in greater bending flexibility. The same mold can be used for edge bending of different workpieces, offering excellent processing flexibility and versatility. Furthermore, the controllable angle of each bend releases internal stress within the workpiece, enabling the processing of brittle materials such as magnesium alloys. This device achieves bending processing through multiple roll forming processes, resulting in low overall motor power, low energy consumption, and a compact size, thus broadening its application range. It can be used for processing automotive parts, window and door frames, highway guardrails, and other components. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the present invention.

[0021] Figure 2 for Figure 1 A partial structural diagram of the intermediate working head.

[0022] Figure 3 Workpiece machining state Figure 1 .

[0023] Figure 4 Workpiece machining state Figure 2 .

[0024] Figure 5 Workpiece machining state Figure 3 .

[0025] Figure 6 Workpiece machining state Figure 4 .

[0026] Figure 7 The working principle of this invention Figure 1 .

[0027] Figure 8 The working principle of this invention Figure 2 .

[0028] In the diagram, 1 is a crossbeam, 2 is an X-axis guide rail slider mechanism, 3 is an X-axis drive motor, 4 is a Z-axis cantilever, 5 is a Y-axis drive motor, 6 is a Y-axis guide rail slider mechanism, 7 is a flipping motor, 8 is a roller, 9 is a roller pressing wheel, 10 is a roller pressing motor, 11 is a flipping bracket, 12 is a Y-axis cantilever, 13 is a Z-axis guide rail slider mechanism, 14 is a Z-axis drive motor, 15 is a mounting part, 16 is a fixing plate, 17 is a hydraulic cylinder, 18 is a piston rod, 19 is a pressure plate, 20 is a bending die, 21 is a worktable, 22 is a workpiece, and 23 is a connecting bracket. Detailed Implementation

[0029] As shown in the figure, a profile roll forming processing device includes a worktable 21, on which a bending die 20 is mounted. A crossbeam 1 is located above the side of the worktable 21. A connecting bracket 23 is mounted on the crossbeam 1 via an X-axis guide rail slider mechanism 2. An X-axis drive motor 3 is mounted on the connecting bracket 23 to drive the connecting bracket 23 to move along the X-axis. A Z-axis cantilever 4 is connected to the connecting bracket 23 via a Z-axis guide rail slider mechanism 13. The connecting bracket 23 is also equipped with a Z-axis drive mechanism to drive the Z-axis cantilever 4 to move along the Z-axis. Motor 14; The lower end of Z-axis cantilever 4 is connected to Y-axis cantilever 12 via Y-axis guide rail slider mechanism 6. The lower end of Z-axis cantilever 4 is provided with Y-axis drive motor 5 to drive Y-axis cantilever 12 to move along Y-axis. The end of Y-axis cantilever 12 is connected to flip motor 7 via fixing plate 16. The axis of flip motor 7 is parallel to X-axis. The output shaft of flip motor 7 is connected to flip bracket 11. The flip bracket 11 is provided with roller shaft 8. The roller shaft 8 is provided with roller pressing wheel 9. The axis of roller pressing wheel 9 is spatially perpendicular to the axis of flip motor 7.

[0030] Furthermore, a pressure plate 19 is provided above the worktable 21 for pressing and fixing the workpiece 22 onto the upper side of the bending die 20. The pressure plate 19 is located at the lower end of the piston rod 18 of the hydraulic cylinder 17, which is fixed to the bed. The workpiece 22 is fixed by the hydraulic cylinder 17, which has a large clamping force, and the workpiece 22 is not easy to move after being positioned, ensuring the smooth progress of processing.

[0031] In order to protect the surface of the workpiece 22 from being pinched, a pad is provided on the lower side of the pressure plate 19.

[0032] Furthermore, the bending die 20 is fixed to the corner of the workbench 21 by screws.

[0033] Furthermore, the flipping bracket 11 is equipped with a roller motor 10, and the output shaft of the roller motor 10 is connected to the roller shaft 8. Under the operation of the roller motor 10, the rotation of the roller 9 is driven by the roller motor 10, and its active rotation is consistent with the X-axis, so that the surface of the workpiece is not easily scratched during the forming process.

[0034] To improve the stability and machining accuracy of the device, the crossbeam 1 is mounted on the bed via the mounting part 15. This structure ensures that the crossbeam 1 and the worktable 21 are relatively fixed in position, thereby improving machining accuracy.

[0035] The working process of the profile roll forming method using the above-mentioned processing equipment is as follows: Figures 3-6 As shown, it includes the following steps:

[0036] 1) A bending die 20 is installed on the edge of the workbench 21. The bending die 20 includes at least two working surfaces arranged at an angle. The bending die 20 is a contour part with an arc-shaped surface at the bending part.

[0037] 2) Press the workpiece 22 against the upper surface of the bending die 20 so that the end to be bent protrudes from the surface of the worktable 21.

[0038] 3) Move the Y-axis cantilever 12, which moves along the X, Y, and Z axes, to a position corresponding to the workpiece 22. The Y-axis cantilever 12 is equipped with a flip motor 7. The axis of the flip motor 7 is parallel to the X-axis. The output shaft of the flip motor 7 is connected to the flip bracket 11. The flip bracket 11 is equipped with a roller shaft 8. The roller shaft 8 is equipped with a pressure roller 9. The axis of the pressure roller 9 is spatially perpendicular to the axis of the flip motor 7. The pressure roller 9 presses against the end of the workpiece 22.

[0039] 4) The flipping motor 7 first bends the end of the workpiece 22 at a certain angle, and then drives the roller 9 to move axially. The roller 9 presses against the surface of the workpiece 22, so that the workpiece 22 is bent at a certain angle.

[0040] 5) The flipping motor 7 rotates again at a certain angle, and at the same time moves in the Z-axis and Y-axis directions to ensure that the roller 9 always presses against the surface of the workpiece 22. The roller 9 moves again along the X-axis to bend the workpiece 22 to a larger angle. This process is repeated until the workpiece 22 reaches the preset bending angle.

[0041] Based on steps 1)-5) above, the profiles that can be processed include, but are not limited to, automotive parts, door and window frames, and highway guardrails.

[0042] This method is suitable for processing workpieces with a small amount of springback and a certain degree of brittleness. When the roller 9 advances, it reciprocates in the X-axis direction. To eliminate the springback motion of the workpiece 22, the bending angle of the roller 9 in the last pass is 1-5° larger than the preset bending angle.

[0043] like Figure 7 As shown, the bending die 20 can be assembled from multiple unit modules along its length. The unit modules are easy to process, versatile, and easy to replace and install. The unit modules can also have different profiles. For example, the bending die 20 may include parts with two working surfaces and other parts with three working surfaces. The workpiece 22 can be partially bent at one angle, while the remaining parts can be bent at another angle. Alternatively, after partial bending, further bending can be performed at the folded edge to form a partial zigzag bend.

[0044] like Figure 8As shown, the workpiece 22 that needs to be bent includes two segments, L1 and L2, with a notch between them. Segment L1 is bent at 45°, and segment L2 is bent at 90°. Using the above method, both segments L1 and L2 are first bent to 45°, and then segment L2 is bent to 90° to complete the two-segment bend. During the bending process, the same mold can be used for both the 45° and 90° bends, providing greater flexibility and versatility.

[0045] This invention is not limited to the above embodiments. Based on the technical solutions disclosed in this invention, those skilled in the art can make some substitutions and modifications to some of the technical features without creative effort, and all such substitutions and modifications are within the protection scope of this invention.

Claims

1. A profile roll forming process, characterized by It comprises the following steps: 1) installing a bending die on the edge of the workbench, the bending die comprising at least two working surfaces arranged at an included angle; 2) pressing the workpiece against the upper surface of the bending die so that the end to be processed is protruding from the surface of the workbench; 3) moving the Y-axis cantilever end along the X-axis, Y-axis and Z-axis to a position corresponding to the workpiece, the Y-axis cantilever end being provided with a turnover motor, the axis of the turnover motor being arranged parallel to the X-axis, the output shaft of the turnover motor being connected to a turnover bracket, the turnover bracket being provided with a roller shaft, the roller shaft being provided with a roller, the axis of the roller being arranged perpendicular to the axis of the turnover motor, the roller being pressed against the end of the workpiece; 4) the turnover motor first bends the end of the workpiece by a certain angle, then drives the roller to move along the X-axis, the roller being pressed against the surface of the workpiece to bend the workpiece by a certain angle; 5) the turnover motor is rotated by a certain angle again, and simultaneously moves along the Z-axis and the Y-axis to ensure that the roller is always pressed against the surface of the workpiece, the roller is moved along the X-axis again to bend the workpiece by a larger angle, and the process is repeated until the workpiece reaches the preset bending angle.

2. A profile roll forming process according to claim 1, characterized in that: The roller reciprocates along the X-axis during the bending process.

3. The profile roll forming process of claim 1, wherein: To eliminate the rebound movement of the workpiece, the roller bending angle of the last pass is 1-5° larger than the preset bending angle.

4. The profile roll forming process of claim 1, wherein: A crossbeam is arranged above the side of the workbench, the crossbeam being provided with a connecting bracket through an X-axis guide rail sliding block mechanism, the connecting bracket being provided with an X-axis drive motor for driving the connecting bracket to move along the X-axis; the connecting bracket is further provided with a Z-axis cantilever through a Z-axis guide rail sliding block mechanism, the connecting bracket being provided with a Z-axis drive motor for driving the Z-axis cantilever to move along the Z-axis; the lower end of the Z-axis cantilever is connected to a Y-axis cantilever through a Y-axis guide rail sliding block mechanism, and the lower end of the Z-axis cantilever is provided with a Y-axis drive motor for driving the Y-axis cantilever to move along the Y-axis.

5. The method of claim 1, wherein: A pressing plate is arranged above the workbench for pressing and fixing the workpiece on the upper side of the bending die, the pressing plate being arranged at the lower end of the piston rod of an oil cylinder, the oil cylinder being fixed on the bed, and the lower side of the pressing plate being provided with a backing plate.

6. The profile roll forming process of claim 1 wherein: The bending die is fixed on the corner position of the workbench through screws.

7. A profile roll forming process according to any one of claims 1 to 6, characterized in that: The turnover bracket is provided with a roller pressing motor, the output shaft of the roller pressing motor being connected to the roller shaft.

8. The method of claim 4, wherein: The crossbeam is mounted on the bed through a mounting portion.

9. A profile roll forming process according to any one of claims 1 to 6, characterized in that: The bending die is composed of multiple unit modules in the length direction.

10. A profile processed by a profile roll forming process, characterized by: The steps of 1) to 5) according to claim 1 are used for processing.

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