High-energy-absorption light-weight rolling profile as well as processing method and application of high-energy-absorption light-weight rolling profile

Abstract

The invention provides a high-energy-absorption light-weight rolling profile which is of a closed structure shaped like a Chinese character'ri 'and formed by multiple times of cold bending of a steel plate and comprises a first cavity and a second cavity which are arranged side by side, and the first cavity and the second cavity are separated through a double-layer reinforcing rib. The profile has sufficient rigidity; compared with other profiles with the same size and weight, the aluminum alloy profile has a high energy absorption effect, has the same strength and bending resistance, and meets the requirements of light weight and national collision regulations. The invention further provides a machining method of the rolling profile. The first cavity and the second cavity are formed by bending relative inner circles. The first cavity is firstly closed and is subjected to first-time welding forming; and then closing of the second cavity is completed, second-time welding forming is carried out, and finally the two cavities are connected into a whole. The machining method is low in machining difficulty and high in forming efficiency, machining cost is reduced, high-speed production of products is achieved, and large-scale industrial popularization is facilitated.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive profiles, and particularly relates to a high energy-absorbing and lightweight roll-formed profile, its processing method and application. Background Art

[0002] With the popularization of the automotive industry, people are paying more and more attention to the safety performance of automobiles. The safety performance of the automotive safety protection system is particularly important, especially for various safety structural components that have an important impact on the safety performance of automobiles, such as automotive anti-collision beams, battery side beams, etc. The main functions of these safety structural components are to enhance the strength of the automobile, absorb impact force, and reduce the personal injuries and deaths of drivers and passengers during automobile collisions. Therefore, in order to improve the body safety performance, while ensuring the product quality, it is necessary to continuously improve and develop a high energy-absorbing, high-strength, and lightweight safety structural component.

[0003] Currently, when traditional roll-formed profiles cannot meet the requirements of high energy absorption and high flexural performance, the strength of the profiles is often increased by increasing the material thickness and other methods to improve the anti-collision performance of the safety structural components. However, this way of simply increasing the thickness cannot meet the design requirement of automotive lightweighting. Therefore, profiles with complex cross-sections have emerged, and the safety collision performance of the profiles is improved through the interconnection of the profiles. For example, double-support leg profiles increase the number of cavities of the profiles, although the anti-collision performance of the safety structural components is improved; however, the cross-section is complex, there are many forming blind areas, and it is difficult to control the forming accuracy; secondly, the complex cross-section increases the material length, which also does not meet the design requirement of automotive lightweighting. Therefore, how to develop a more reasonable profile structure while ensuring the high strength and lightweight of the profile and further improving the safety performance has become an important topic being studied by the industry insiders. Summary of the Invention

[0004] To solve the above problems existing in the prior art, the purpose of the present invention is to provide a high energy-absorbing and lightweight roll-formed profile.

[0005] To solve the above technical problems, the technical solution adopted by the present invention is:

[0006] A high energy-absorbing and lightweight roll-formed profile, the roll-formed profile is a "day"-shaped closed structure formed by symmetrically cold-bending a steel plate multiple times, including a first cavity and a second cavity arranged in parallel, and the first cavity and the second cavity are separated by a double-layer reinforcing rib.

[0007] A further improvement of the present invention is that the first cavity and the second cavity are arranged symmetrically left and right along the double-layer reinforcing rib.

[0008] A further improvement of the present invention is that the rolled profile includes a first upper wall, a second upper wall, a left side wall, a right side wall, a lower wall, a first center rib, and a second center rib; the first upper wall, the left side wall, a portion of the lower wall, and the first center rib together form a first cavity, and the second upper wall, the right side wall, a portion of the lower wall, and the second center rib together form a second cavity; the first center rib and the second center rib are welded together to form a double-layer reinforcement rib, and the ends of the double-layer reinforcement rib are welded to the lower wall.

[0009] A further improvement of the present invention is that the connection between the end of the double-layer reinforcement rib and the lower wall is made by hook welding, bending welding or vertical welding.

[0010] A further improvement of the present invention is that when the double-layer reinforcement ribs are connected by hook welding, the end of the first center rib extends a first hook pointing to the inside of the first cavity, and the end of the second center rib extends a second hook pointing to the inside of the second cavity, and the first hook, the second hook and the double-layer reinforcement rib constitute a Y-shaped reinforcement rib structure.

[0011] A further improvement of the present invention is that an inverted V-shaped rib matching the Y-shaped reinforcing rib structure is provided on the lower wall.

[0012] A further improvement of the present invention is that when the double-layer reinforcement ribs are connected by bending and welding, the end of the first center rib extends a first folded edge, and the end of the second center rib extends a second folded edge; the first folded edge and the second folded edge are both parallel to the lower wall.

[0013] A further improvement of the present invention is that a U-shaped groove for reinforcement is provided on the upper wall and / or lower wall of the first cavity and the second cavity.

[0014] The processing method of the high energy absorption and lightweight roll-formed profile comprises the following steps:

[0015] S1. Uncoiling, leveling and pre-punching the sheet;

[0016] S2, sending the leveled plate into the cold roll forming unit for high-precision symmetrical forming, the first cavity and the second cavity are formed by relative inner bending; during processing, the first cavity is formed first, the first cavity is closed by the first welding, and then the second cavity is formed, and at the same time, the second welding is performed to complete the closing of the second cavity and connect the two cavities into one, forming a roll-formed profile with a complete structure;

[0017] S3. According to the required curvature requirements, adjust the curvature radius of the rolled profile and perform roller arc forming;

[0018] S4. According to the required length, the rolled profile is cut and cut to a fixed length to obtain a high energy absorption and lightweight rolled profile.

[0019] The step S2 specifically comprises the following steps:

[0020] S21, partially symmetrical molding

[0021] The profile enters the first cold roll forming unit, and firstly the inner top angles of the two cavities are symmetrically formed. Later, the bottom surface is reversed to control the rebound and avoid empty bending, so as to finish the forming of the inner top angles on both sides; then the outer top angles on both sides are symmetrically formed to a certain angle, and the bottom surface is kept in a reversed state, and the outer top angles on both sides are kept in a solid pressure state; then the outer top angle forming is suspended, and the bottom angles on both sides are symmetrically formed, and the bottom surface is kept in a reversed state, so that the outer bottom angles on both sides are always pressed to a certain angle, and finally the bottom surface is flattened, so that the high-precision symmetrical forming is completed;

[0022] S22, molding of the first cavity

[0023] The left bottom corner is formed quickly by multiple bending, and the left top corner is formed by multiple bending and springback control at the same time; then the right bottom corner is formed slowly, and the roller pressing space is reserved in the middle position through the forming speed difference on both sides to facilitate the closing of the first cavity; when the first cavity is closed, it enters the first welding mechanism for one welding to complete the closing of the first cavity;

[0024] S23, molding of the second cavity

[0025] The profile enters the second cold-bending forming unit, and is formed into the right bottom corner by multiple bending, and the right top corner is formed by multiple bending and springback control, thereby completing the closure of the second cavity. When the second cavity is closed, the profile enters the second welding mechanism for secondary welding, and the second hook is welded to the lower wall (3), and the two cavities are connected into one, thereby forming a closed roll-formed profile.

[0026] In the present invention, when the double-layer reinforcement ribs are connected by edge welding, after the plate enters the first cold bending forming unit, the inverted V-shaped ribs of the bottom wall and the edges at both ends of the plate are first symmetrically bent, and then the inner top angles of the two cavities are symmetrically formed after completion; when the double-layer reinforcement ribs are connected by edge folding welding, after the plate enters the first cold bending forming unit, the edges at both ends of the plate are first symmetrically bent, and then the inner top angles of the two cavities are symmetrically formed after completion.

[0027] In the present invention, the rolled profile obtained in step S23 is firstly passed through a sizing unit for more accurate cross-sectional precision control, and then enters step S3.

[0028] In the present invention, the primary welding and the secondary welding are arc welding or fusion welding; the arc welding is selected from tungsten inert gas shielded arc welding, metal inert gas shielded arc welding, carbon dioxide gas shielded arc welding or plasma arc welding, and the fusion welding is selected from electron beam welding or laser welding.

[0029] The application of the high energy absorption and lightweight roll-formed profile can be used in the production of automotive anti-collision beams, battery side beams or other side beam type profiles.

[0030] Due to the adoption of the above technical solution, the technical progress achieved by the present invention is:

[0031] The present invention discloses a high energy absorption and lightweight roll-formed profile, which has two closed cavities arranged side by side, so that the profile has sufficient rigidity; the two cavities are connected into one body by laser welding, and two layers of reinforcing ribs are formed in the middle. The reinforcing ribs effectively improve the strength and bending resistance of the roll-formed profile. Especially when resisting the impact force from a frontal collision, the bending resistance of the profile during impact can be significantly improved, and the collision bending deformation of the profile can be effectively resisted.

[0032] It has been experimentally proven that compared with the traditional roll-formed profiles in the shape of a Japanese character, a Chinese character "mu", and a "B" character with the same size and weight, the roll-formed profile of the present invention not only ensures the strength and rigidity of the profile itself, but also significantly increases the energy absorption peak value of the roll-formed profile, meeting the national collision regulation requirements of high energy absorption and lightweight. It is especially suitable for use as a safety structural member in the vehicle safety protection system, such as automotive anti-collision beams, battery side beams or other side beam type profiles, etc.

[0033] The present invention also provides a forming and processing method, which realizes the multi-bending forming of the sheet by means of roll forming, and has a low processing difficulty; through integrated processing on an automated roll stamping production line, the stamping, roll forming and welding processes are integrated, realizing the efficient utilization of raw materials, with a high forming efficiency, reducing the processing cost, enabling the high-speed production of products, and being conducive to large-scale industrial promotion.

[0034] The processing method of the present invention can be used to process and produce automotive anti-collision beams, battery side beams or other side beam type profiles. When used as a battery side beam type profile, it is easier to assemble and connect. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a sectional view of Embodiment 1 of the present invention;

[0036] Figure 2 It is a sectional view of Embodiment 2 of the present invention;

[0037] Figure 3 It is a sectional view of Embodiment 3 of the present invention;

[0038] Figure 4 It is a sectional view of Embodiment 4 of the present invention;

[0039] Figure 5 It is a sectional view of Embodiment 5 of the present invention;

[0040] Figure 6 It is a sectional view of Embodiment 6 of the present invention;

[0041] Figure 7 is a truncated schematic diagram of Example 7 of the present invention;

[0042] Figure 8 It is a truncated schematic diagram of Example 8 of the present invention;

[0043] Fig. 9 is a truncated schematic diagram of Example 9 of the present invention;

[0044] Fig.10 It is a schematic diagram of the cross section of the roll-formed profile of the present invention in the performance test;

[0045] Fig.11 It is a sectional schematic diagram of the traditional Japanese-shaped high-strength steel anti-collision beam structure in the performance test;

[0046] Fig.12 This is a sectional schematic diagram of the U-shaped high-strength steel anti-collision beam structure in the performance test;

[0047] Fig.13 It is a schematic diagram of the cross section of the B-shaped high-strength steel anti-collision beam in the performance test;

[0048] Fig.14 The bending moment curves of four profile specimens;

[0049] Fig.15 The energy absorption curves of four profile specimens are shown in Figure 2.

[0050] Fig.16 This is a schematic diagram of the forming process flow of the roll-formed profile in Example 1;

[0051] Fig.17 This is a schematic diagram of the key passes for controlling the bottom angle of the first cavity;

[0052] Fig.18 This is a schematic diagram of the key passes for controlling the bottom angle of the second cavity;

[0053] Fig.19 It is a schematic diagram of the processing production line of the present invention;

[0054] In the figure, 1 is the first cavity, 1-1 is the first upper wall, 1-2 is the left side wall, 1-3 is the first middle rib, 1-4 is the first edge hook, 1-5 is the first hem; 2 is the second cavity, 2-1 is the second upper wall, 2-2 is the right side wall, 2-3 is the second middle rib, 2-4 is the second edge hook, 2-5 is the second hem; 3 is the lower wall, 4 is the U-shaped groove, 5 is the welding point, 6 is the decoiler, 7 is the leveling, shearing and butt welding mechanism, 8 is the punching mechanism, 9 is the servo feeding, 10 is the missed punching detection mechanism, 11 is the pit bridge, 12 is the first cold bending forming unit, 13 is the first welding mechanism, 14 is the second cold bending forming unit, 15 is the second welding mechanism, 16 is the roll arc mechanism; 17 is the cutting mechanism, 18 is the material receiving mechanism. Detailed implementation mode

[0055] The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0056] A high energy absorption and lightweight roll-formed profile, the roll-formed profile is a "day"-shaped closed structure obtained by symmetrically cold bending a steel plate multiple times, including a first cavity 1 and a second cavity 2 arranged in parallel, and the first cavity 1 and the second cavity 2 are separated by a double-layer reinforcing rib.

[0057] As Figure 1 shown, the roll-formed profile includes a first upper wall 1-1, a second upper wall 2-1, a left side wall 1-2, a right side wall 2-2, a lower wall 3, a first middle rib 1-3 and a second middle rib 2-3. The first upper wall 1-1, the left side wall 1-2, the left half of the lower wall 3, and the first middle rib 1-3 enclose to form the first cavity 1, and the second upper wall 2-1, the right side wall 2-2, the right half of the lower wall 3, and the second middle rib 2-3 enclose to form the second cavity 2; the first middle rib 1-3 and the second middle rib 2-3 are arranged side by side and welded together to form a double-layer reinforcing rib, and the ends of the double-layer reinforcing rib are welded to the lower wall 3 to realize the closure of the first cavity 1 and the second cavity 2. The first cavity 1 and the second cavity 2 are formed by relative inner winding and bending; the first cavity 1 is first closed and welded for the first time to form; then the second cavity 2 is closed, and at the same time, the second welding is carried out to form, and finally the two cavities are connected into one body.

[0058] The first cavity 1 and the second cavity 2 are arranged symmetrically left and right along the double-layer reinforcing rib, that is, the lengths of the first middle rib 1-3 and the second middle rib 2-3 are the same, and the double-layer reinforcing rib can provide enhanced supporting force for the first cavity 1 and the second cavity 2 at the same time. If the lengths of the first middle rib 1-3 and the second middle rib 2-3 are inconsistent, then a section of the longer middle rib will be supported by a single root, and its supporting strength is significantly lower. Therefore, the strength and impact resistance of the cavity on that side decrease, and the strengths of the two cavities on both sides are inconsistent, which affects the overall strength of the roll-formed profile and its safety performance.

[0059] Considering the overall strength of the rolled profile, the first cavity 1 and the second cavity 2 are preferably rectangular, that is, the left side wall 1-2, the right side wall 2-2, the first center rib 1-3, and the second center rib 2-3 are of the same length. According to the use requirements of the rolled profile, the rolled profile of the present invention can also be appropriately deformed, for example, the first cavity 1 and the second cavity 2 are deformed into a trapezoid with double-layer reinforcement ribs symmetrically arranged, the left side wall 1-2 and the right side wall 2-2 are of the same length, the first center rib 1-3 and the second center rib 2-3 are of the same length, and the length of the left side wall 1-2 / right side wall 2-2 is less than the length of the first center rib 1-3 / second center rib 2-3; in this case, the rolled profile can also maintain a relatively high overall strength.

[0060] There are three ways to connect the end of the double-layer reinforcement rib to the lower wall 3, namely, hook welding, bending welding and vertical welding. Among the three welding methods, hook welding has the highest connection strength and vertical welding has the lowest connection strength, which can be selected according to the strength requirements of the specific use purpose of the profile.

[0061] When the hook welding connection method is adopted, the end of the first central rib 1-3 extends to form a first hook 1-4 pointing to the inside of the first cavity 1, and the end of the second central rib 2-3 extends to form a second hook 2-4 pointing to the inside of the second cavity 2. The first hook 1-4 and the second hook 2-4 are symmetrically arranged along the double-layer reinforcement rib. The first hook 1-4, the second hook 2-4 and the double-layer reinforcement rib form a Y-shaped reinforcement rib structure.

[0062] The angle between the first hook edge 1-4 and the second hook edge 2-4 is an acute angle, preferably 30° to 60°. The first hook edge 1-4 and the first center rib 1-3, and the second hook edge 2-4 and the second center rib 2-3 are both rounded and smoothly transitioned.

[0063] The stacking length between the first hook edge 1-4, the second hook edge 2-4 and the lower wall 3 is not less than 8 mm, and a weld extending along the length direction is formed between the first hook edge 1-4, the second hook edge 2-4 and the lower wall 3 to ensure the welding strength and the impact resistance of the final profile product.

[0064] In order to increase the stability of welding, an inverted V-shaped rib 3-1 matching with the Y-shaped reinforcing rib structure is provided on the lower wall 3. The Y-shaped reinforcing rib structure and the inverted V-shaped rib 3-1 form a matching surface for strengthening the welding connection.

[0065] When the double-layer reinforcement ribs are connected by bending and welding, the end of the first center rib 1-3 extends to a first folded edge 1-5, and the end of the second center rib 2-3 extends to a second folded edge 2-5; the first folded edge 1-5 and the second folded edge 2-5 are parallel to the lower wall 3 and fixed by welding. The first folded edge 1-5 and the first center rib 1-3, and the second folded edge 2-5 and the second center rib 2-3 are both rounded and smoothly transitioned.

[0066] The bends of the first cavity 1 and the second cavity 2 are also rounded corners, reducing stress points and enhancing anti-collision performance. When stressed, the impact force is synchronously transmitted along the symmetrically arranged plates, with more uniform stress and no obstacle dead angles.

[0067] U-shaped grooves 4 for reinforcement are provided on the upper wall and / or lower wall of the first cavity 1 and the second cavity 2. On the one hand, the U-shaped grooves 4 can strengthen the upper wall and / or lower wall, and on the other hand, they can reduce the thickness of the used plates under the conditions of the same strength and stiffness. The width and depth of the U-shaped grooves 4 can be adaptively changed according to the boundary conditions of the product to increase the stiffness of the body structure.

[0068] The left side wall 1-2, the right side wall 2-2, and the lower wall 3 are all smooth planes without welded joints, with relatively high surface quality and being more easily assembled and connected during use.

[0069] The following are 3 structural embodiments of the high energy-absorbing and lightweight roll-formed profile of the present invention. Appropriate deformations and derivatives based on these three embodiments are all within the protection scope of the present invention.

[0070] Example 1

[0071] See Figure 1 , the roll-formed profile is a "day"-shaped closed structure obtained by symmetrically cold-bending a steel plate multiple times. The roll-formed profile includes a first upper wall 1-1, a second upper wall 2-1, a left side wall 1-2, a right side wall 2-2, a lower wall 3, a first middle rib 1-3, and a second middle rib 2-3. The first upper wall 1-1, the left side wall 1-2, the left half of the lower wall 3, and the first middle rib 1-3 enclose to form a first cavity 1, and the second upper wall 2-1, the right side wall 2-2, the right half of the lower wall 3, and the second middle rib 2-3 enclose to form a second cavity 2; the first middle rib 1-3 and the second middle rib 2-3 are arranged side by side and welded together to form a double-layer reinforcing rib, and the ends of the double-layer reinforcing rib are welded to the lower wall 3 to realize the closure of the first cavity 1 and the second cavity 2. Both the first cavity 1 and the second cavity 2 are rectangular cavities with the same size.

[0072] The end of the first middle rib 1-3 extends a first hook edge 1-4 pointing to the inside of the first cavity 1, and the end of the second middle rib 2-3 extends a second hook edge 2-4 pointing to the inside of the second cavity 2. The first hook edge 1-4, the second hook edge 2-4, the first middle rib 1-3, and the second middle rib 2-3 together form a Y-shaped reinforcing rib structure. An inverted V-shaped rib 3-1 matching the Y-shaped reinforcing rib structure is provided on the lower wall 3. The Y-shaped reinforcing rib structure and the inverted V-shaped rib 3-1 are welded together after being fitted.

[0073] U-shaped grooves 4 are symmetrically provided on the first upper wall 1 - 1 and the second upper wall 2 - 1 , and the rigidity of the main body structure is increased by strengthening the two upper walls.

[0074] Example 2

[0075] See also Figure 2 The structure of this embodiment is basically the same as that of the embodiment 1, except that: the first upper wall 1-1 and the second upper wall 2-1 are not provided with U-shaped grooves 4, and the four walls of the rolled profile are all planes.

[0076] Example 3

[0077] See also Figure 3 The structure of this embodiment is basically the same as that of embodiment 1, with the difference that the bottom walls of the first cavity and the second cavity are also provided with a U-shaped groove 4, and the upper wall U-shaped groove and the lower wall U-shaped groove of the first cavity are symmetrically arranged, and the upper wall U-shaped groove and the lower wall U-shaped groove of the second cavity are symmetrically arranged.

[0078] Example 4

[0079] See also Figure 4 The structure of this embodiment is basically the same as that of embodiment 1, except that in this embodiment, the double-layer reinforcement ribs and the lower wall are connected by folding welding.

[0080] The end of the first center rib 1-3 is bent inward 90° to form a first folded edge 1-5, and the end of the second center rib 2-3 is bent inward 90° to form a second folded edge 2-5; the first folded edge 1-5 and the second folded edge 2-5 are both parallel to the lower wall 3, and the lower wall is a flat surface, and the two are welded after being fitted together.

[0081] Example 5

[0082] See also Figure 5 The structure of this embodiment is basically the same as that of embodiment 4, the difference being that: no U-shaped groove 4 is provided on the first upper wall 1-1 and the second upper wall 2-1, and the four walls of the rolled profile are all flat.

[0083] Example 6

[0084] See also Figure 6 The structure of this embodiment is basically the same as that of embodiment 4, with the difference that the bottom walls of the first cavity and the second cavity are also provided with a U-shaped groove 4, and the upper wall U-shaped groove and the lower wall U-shaped groove of the first cavity are symmetrically arranged, and the upper wall U-shaped groove and the lower wall U-shaped groove of the second cavity are symmetrically arranged.

[0085] Example 7

[0086] See also Figure 7 The structure of this embodiment is basically the same as that of embodiment 1, except that in this embodiment, the double-layer reinforcement ribs and the lower wall are connected by vertical welding.

[0087] The first center rib 1-3 and the second center rib 2-3 are in a straight line shape, and the lower wall is a flat surface. The first center rib and the second center rib are vertically welded to the lower wall by vertical welding.

[0088] Example 8

[0089] See also Figure 8 The structure of this embodiment is basically the same as that of embodiment 7, the difference being that: the first upper wall 1-1 and the second upper wall 2-1 are not provided with U-shaped grooves 4, and the four walls of the rolled profile are all planes.

[0090] Example 9

[0091] See also Fig. 9 The structure of this embodiment is basically the same as that of embodiment 7, with the difference being that the bottom walls of the first cavity and the second cavity are also provided with a U-shaped groove 4, and the upper wall U-shaped groove and the lower wall U-shaped groove of the first cavity are symmetrically arranged, and the upper wall U-shaped groove and the lower wall U-shaped groove of the second cavity are symmetrically arranged.

[0092] In the above embodiment, the U-shaped groove 4 is arranged along the length direction of the plate, and its length is the same as the length of the plate, and its width and depth can be adaptively changed according to the boundary conditions of the product to increase the rigidity of the main body structure. In addition, when used as a battery shell side beam, more straight mounting surfaces are required, and there is no U-shaped groove on the upper wall and the lower wall.

[0093] Regarding the welding method of the ends of the first center rib and the second center rib, it can be selected according to the difficulty of processing. Whether it is edge welding, bending welding, or vertical welding, after stable welding, the supporting strength of the product can be guaranteed, which belongs to the protection scope of the present invention.

[0094] Aiming at the strength and energy absorption performance of the rolled profile, several different structures of rolled profiles were used for experimental comparison.

[0095] Sample 1: Using Fig.10 The Japanese-shaped high-strength steel anti-collision beam of the present invention is made of HC1030-1300MS high-strength steel, with a plate thickness of 1.5 mm and a cross-sectional size of 125 mm×50 mm, and is marked as 1#;

[0096] Sample 2: Using Fig.11 The traditional Japanese-shaped high-strength steel anti-collision beam structure shown is made of HC1030-1300MS high-strength steel, with a plate thickness of 1.61mm and a cross-section size of 125mm×50mm, marked as 2#;

[0097] Specimen 3: Adopt Fig.12 the eye-shaped high-strength steel anti-collision beam structure shown in the figure. The material is selected as HC1030-1300MS high-strength steel. The thickness of the embedded part plate is 1.78 mm, the thickness of the peripheral part plate is 1.2 mm, the section size is 125 mm×50 mm, and it is marked as 3#;

[0098] Specimen 4: Adopt Fig.13 the B-shaped high-strength steel anti-collision beam shown in the figure. The material is selected as HC1030-1300MS high-strength steel. The plate thickness is 1.54 mm, the section size is 125 mm×50 mm, and it is marked as 4#;

[0099] Perform a three-point bending performance test on the above four cross-sections. The bending moment curve is shown in Fig.14 and the energy absorption curve is shown in Fig.15 . The test results are shown in the following table.

[0100]

[0101] It can be seen from the above data that the bending resistance performance and overall quality of the 1# rolled profile are basically the same as those of the 2#, 3#, and 4# rolled profiles; however, the peak energy absorption of the 1# rolled profile is the highest (7047.72 J), significantly higher than that of the other three groups of rolled profiles, proving that the energy absorption effect of the profile of the present invention is excellent.

[0102] The present invention has two cavities and double-layer reinforcing ribs, making the profile have sufficient rigidity; compared with the traditional daily-shaped, eye-shaped, and B-shaped rolled profiles of the same size and weight, it has a higher energy absorption effect, and at the same time has the same strength and bending resistance performance, meeting the requirements of lightweight and national collision regulations.

[0103] The processing method of the high energy absorption lightweight rolled profile includes the following steps:

[0104] S1. Uncoil, level, and pre-punch the plate.

[0105] S2. Feed the leveled plate into a cold bending forming machine set for high-precision symmetric forming. Both the first cavity and the second cavity are formed by relative inner winding and bending; during processing, first complete the forming of the first cavity, complete the sealing of the first cavity through the first welding, then complete the forming of the second cavity, and at the same time perform the second welding to complete the sealing of the second cavity and connect the two cavities into one body to form a structurally complete rolled profile.

[0106] S3. Adjust the rolled profile to the required radian radius according to the required radian requirement for roll bending forming.

[0107] S4. Cut and下料 the rolled profile to the required length to obtain the high energy absorption lightweight rolled profile.

[0108] The step S2 is a roll forming process of the profile, which specifically includes the following steps:

[0109] S21, partially symmetrical molding

[0110] The profile enters the first cold roll forming unit, and firstly the inner top angles of the two cavities are symmetrically formed. Later, the bottom surface is reversed to control the rebound and avoid empty bending, so as to finish the forming of the inner top angles on both sides; then the outer top angles on both sides are symmetrically formed to a certain angle, and the bottom surface is kept in a reversed state, and the outer top angles on both sides are kept in a solid pressure state; then the outer top angle forming is suspended, and the bottom angles on both sides are symmetrically formed, and the bottom surface is kept in a reversed state, so that the outer bottom angles on both sides are always pressed to a certain angle, and finally the bottom surface is flattened, so that the high-precision symmetrical forming is completed;

[0111] S22, molding of the first cavity

[0112] The left bottom corner is formed quickly by multiple bending, and the left top corner is formed by multiple bending and springback control at the same time; then the right bottom corner is formed slowly, and the roller pressing space is reserved in the middle position through the forming speed difference on both sides to facilitate the closing of the first cavity; when the first cavity is closed, it enters the first welding mechanism for one welding to complete the closing of the first cavity;

[0113] S23, molding of the second cavity

[0114] The profile enters the second cold roll forming unit, and is formed into the right bottom corner by multiple bending, and the right top corner is formed by multiple bending and springback control, completing the closing of the second cavity; when the second cavity is closed, it enters the second welding mechanism for secondary welding, and the second hook is welded to the lower wall, and the two cavities are connected into one, forming a closed roll-pressed profile;

[0115] S24, precision control

[0116] The rolled profile obtained in step S23 is firstly passed through a sizing unit for more precise cross-sectional accuracy control, and then enters step S3.

[0117] When the double-layer reinforcement ribs are connected by edge welding, after the plate enters the first cold bending forming unit, the inverted V-shaped ribs of the bottom wall and the edges at both ends of the plate are first symmetrically bent, and then the inner top angles of the two cavities are symmetrically formed after completion; when the double-layer reinforcement ribs are connected by edge folding welding, after the plate enters the first cold bending forming unit, the edges at both ends of the plate are first symmetrically bent, and then the inner top angles of the two cavities are symmetrically formed after completion.

[0118] The primary welding and the secondary welding are arc welding or fusion welding; the arc welding is selected from tungsten inert gas shielded arc welding, metal inert gas shielded arc welding, carbon dioxide gas shielded arc welding or plasma arc welding, and the fusion welding is selected from electron beam welding or laser welding.

[0119] Refer to Fig.16 , taking the "day" - shaped cross - section shown in Figure 1 as an example, its forming process requires a total of 9 steps and 41 bends for forming.

[0120] The first step is to symmetrically form the V - shaped feature on the bottom surface, which is formed through 3 bends;

[0121] The second step is to symmetrically form the side hook edges, which is formed through 4 bends;

[0122] The third step is to symmetrically form the U - shaped grooves on the upper arms on both sides, which is formed through 4 bends;

[0123] It should be noted that the V - shaped feature on the bottom surface and the side hook edges are formed simultaneously. The 3rd bend of the V - shaped feature is completed first, followed by the 4th bend of the side hook edges. At the same time, the U - shaped grooves start to be formed and are completed until the 7th bend;

[0124] The fourth step is to symmetrically form the inner top corners of the two cavities, and use the reverse bending of the bottom surface to control springback and avoid empty bending, so as to finish the forming of the inner top corners on both sides precisely, which is formed through 7 bends;

[0125] The fifth step is to symmetrically form the outer top corners on both sides to a certain angle, with the bottom surface remaining in the reverse - bent state and keeping the outer top corners in a solid - pressed state, which is formed through 5 bends;

[0126] The sixth step is to symmetrically form the bottom corners on both sides, with the bottom surface remaining in the reverse - bent state, making the outer bottom corners on both sides be solid - pressed to a certain angle, and finally flatten the bottom surface, which is formed through 4 bends;

[0127] The seventh step is to complete the closure of the first cavity. First, quickly form the left bottom corner through multiple bends, and at the same time, multiple bends and springback control are accompanied by the formation of the left top corner; secondly, slowly form the right bottom corner, and leave a roller solid - pressing space in the middle position through the forming speed difference on both sides to facilitate the closure of the first cavity, which is formed through 6 bends;

[0128] The eighth step is to complete the closure of the second cavity, which is formed through 9 bends by forming the right bottom corner through multiple bends and at the same time, multiple bends and springback control are accompanied by the formation of the right top corner;

[0129] The ninth step is to conduct more precise cross - section accuracy control through a sizing unit, which is controlled through 3 bends.

[0130] Refer to Fig.17 , the key bends for controlling the bottom corners of the first cavity are the 24th, 25th, and 26th bends. At the 24th bend, an auxiliary tool is installed with an inclined roller to solid - press the bottom corner, reducing the empty - bend bends to reduce the corner stress; at the 25th and 26th bends, horizontal blocks are set to cooperate with the outer rollers to solid - press the bottom corner, reducing the empty - bend to reduce the corner stress.

[0131] join Fig.18 The key passes for controlling the bottom angle of the second cavity are passes 30, 31 and 32. The above groups all use auxiliary tools to install inclined rollers to press the bottom angle, reducing the number of empty bend passes to reduce fillet stress.

[0132] After the first cavity is formed, the profile enters the first welding mechanism, and the first hook edge is welded to the inverted V-shaped feature of the lower wall through the first welding mechanism. After multiple bendings, the second cavity is formed. When the second cavity is closed, the second hook edge is welded to the inverted V-shaped feature of the lower wall and the top of the two layers of middle ribs at the same time, and finally the two cavities are connected into one, forming a closed roll-pressed profile.

[0133] The welding method between the first hook edge and the lower wall, between the second hook edge and the lower wall, and between the first center rib and the second center rib can be selected as Y-shaped welding as shown in Examples 1 to 3, 90° inward bending welding as shown in Examples 4 to 6, or vertical standing welding as shown in Examples 7 to 9. When stack welding is used, the length of the welded stacked material portion is not less than 3 times the material thickness to ensure the welding strength and the impact resistance of the final profile product.

[0134] The welding methods between the first hook edge and the lower wall, between the second hook edge and the lower wall, and between the first center rib and the second center rib are all arc welding or fusion welding, which can be selected according to the actual processing capacity and convenience of the manufacturer. Specifically, the arc welding can be tungsten inert gas shielded arc welding, metal inert gas shielded arc welding, carbon dioxide gas shielded arc welding or plasma arc welding, and the fusion welding can be electron beam welding or laser welding; laser welding is preferably used, which has fast welding speed and high welding strength.

[0135] If a U-shaped groove for reinforcement is required on the first upper arm, the second upper arm or the lower wall of the rolled profile, after the plate enters the first cold bending forming unit, the U-shaped groove is first formed, and then the inner top angles of the two cavities are symmetrically formed.

[0136] If the profile needs to be provided with a plurality of mounting holes for mounting other accessories, the plate is first pre-punched after being unrolled and leveled, and then enters the first cold roll forming unit for bending and forming.

[0137] The molding production line based on the above processing method, such as Fig.19 As shown, it includes an uncoiler 6, a leveling shearing and welding mechanism 7, a punching mechanism 8, a servo feeding 9, a missing punching detection mechanism 10, a pit bridge 11, a first cold bending forming unit 12, a first welding mechanism 13, a second cold bending forming unit 14, a second welding mechanism 15, a roller arc mechanism 16, a cutting mechanism 17, and a material receiving mechanism 18.

[0138] Among them, the unwinder 6, the leveling shearing and welding mechanism 7, the punching mechanism 8, the servo feeding 9, the missing punching detection mechanism 10, and the pit bridge 11 belong to the feeding section before rolling, which are used to sort the plate before rolling. The first cold bending forming unit 12 and the first welding mechanism 13 belong to the first forming section, and the second cold bending forming unit 14 and the second welding mechanism 15 belong to the second forming section, which are used to cold bend the plate in multiple passes to form a three-dimensional profile. The roller arc mechanism 16, the cutting mechanism 17, and the material receiving mechanism 18 belong to the post-rolling shaping section. The processed profile is sheared to a fixed length by the cutting mechanism to obtain a high-energy-absorbing and lightweight rolled profile.

[0139] Specifically, the uncoiler and leveler are used to uncoil and level the plate.

[0140] In addition, in the actual processing process, due to the need to replace the material coil of the plate, the outlet end of the leveling machine is also provided with a shearing and welding mechanism to realize the cutting of the head and tail of the metal plate when the metal plate coil is replaced, and the front and rear steels are welded together to achieve continuous feeding, reduce material waste and improve production efficiency.

[0141] According to the installation and connection requirements of the rolled profile and other components, a punching mechanism is also provided between the feeding mechanism and the cold roll forming unit to pre-punch out the product installation holes. The punching mechanism includes a servo feeding unit, a punching unit and a missing punching detection unit arranged in sequence. The servo feeding unit is an electronic auxiliary device before pre-punching, which is used to assist the pre-punching fixed-length feeding; the punching unit is used to punch the holes on the product in advance; and the missing punching detection unit is used to check whether the punching unit has any missing punching.

[0142] Since the punching speed is not necessarily consistent with the feeding speed of the metal sheet, a pit bridge is provided downstream of the punching mechanism to store the metal sheet material. This ensures that the front and rear processing are not affected when the front and rear production speeds are different. It is mainly used for the punching mechanism and the front and rear material strip correction.

[0143] The first bending forming unit and the second cold bending forming unit are both provided with a plurality of pressing rollers for forming the first cavity and the second cavity respectively. The setting of the pressing roller structure is determined by the cavity structure.

[0144] The welder in the first welding mechanism can be an arc welder or a fusion welder, preferably a single-head laser welder; the welder in the second welding mechanism can be an arc welder or a fusion welder, preferably a double-head laser welder.

[0145] The second welding mechanism is provided with a laser welding machine, and the second hook edge and the lower wall, and the first center rib and the end of the second center rib are synchronously welded by two laser welding heads arranged upper and lower.

[0146] In addition, the production line also includes some processing auxiliary mechanisms, such as material receiving mechanism, electric control mechanism, safety protection mechanism, etc. Among them, the material receiving mechanism is set downstream of the cutting mechanism to assist manual unloading; the electric control mechanism is used for the whole line control of the roller pressing line; the safety protection mechanism is used for the whole line human-machine isolation, mainly including isolation nets, safety doors, safety gratings, etc. Since these auxiliary mechanisms are not the invention of the present invention, they are all prior art and will not be described here.

[0147] The high energy absorption and lightweight rolled profile of the present invention can be used to produce automobile anti-collision beams, battery side beams or other side beam types. It can significantly reduce product quality while maintaining the strength and energy absorption performance of the profile, meeting the requirements of lightweight.

[0148] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made according to the scope of the patent application of the present invention should fall within the scope of the present invention.

Claims

1. A high energy absorption and lightweight roll-formed profile, characterized in that: The roll-formed profile is a "day"-shaped closed structure formed by cold-bending a steel plate multiple times, including a first cavity (1) and a second cavity (2) arranged side by side. The first cavity (1) and the second cavity (2) are separated by a double-layer reinforcing rib; the first cavity (1) and the second cavity (2) are arranged symmetrically left and right along the double-layer reinforcing rib; The ends of the double-layer reinforcing rib are welded to the lower wall (3), and the welding method of the end of the double-layer reinforcing rib and the lower wall (3) is edge-hooking welding, bending welding or vertical welding.

2. The high energy absorption and lightweight roll-formed profile according to claim 1, characterized in that: The roll-formed profile includes a first upper wall (1-1), a second upper wall (2-1), a left side wall (1-2), a right side wall (2-2), a lower wall (3), a first middle rib (1-3), and a second middle rib (2-3); the first upper wall (1-1), the left side wall (1-2), the lower wall (3), and the first middle rib (1-3) enclose to form the first cavity (1), and the second upper wall (2-1), the right side wall (2-2), the lower wall (3), and the second middle rib (2-3) enclose to form the second cavity (2); the first middle rib (1-3) and the second middle rib (2-3) are welded together to form a double-layer reinforcing rib.

3. The high energy absorption and lightweight roll-formed profile according to claim 2, characterized in that: When the double-layer reinforcing rib is connected by edge-hooking welding, the end of the first middle rib (1-3) extends a first edge-hooking (1-4) pointing to the inside of the first cavity (1), and the end of the second middle rib (2-3) extends a second edge-hooking (2-4) pointing to the inside of the second cavity (2). The first edge-hooking (1-4), the second edge-hooking (2-4), and the double-layer reinforcing rib form a Y-shaped reinforcing rib structure; a reverse V-shaped rib (3-1) matching the Y-shaped reinforcing rib structure is arranged on the lower wall (3); When the double-layer reinforcing rib is connected by bending welding, the end of the first middle rib (1-3) extends a first folded edge (1-5), and the end of the second middle rib (2-3) extends a second folded edge (2-5); both the first folded edge (1-5) and the second folded edge (2-5) are parallel to the lower wall (3).

4. The high energy absorption and lightweight roll-formed profile according to claim 2, characterized in that: U-shaped grooves (4) for reinforcement are arranged on the upper wall and / or the lower wall of the first cavity (1) and the second cavity (2).

5. The method for processing a high energy absorption lightweight roll-formed profile according to any one of claims 1 to 4, characterized in that It includes the following steps: S1. Unroll, level, and pre-punch the sheet. S2. Feed the leveled sheet into a cold bending forming machine set for high-precision symmetric forming. Both the first cavity and the second cavity are formed by relative internal winding and bending; during processing, first complete the forming of the first cavity, complete the enclosure of the first cavity through the first welding, then complete the forming of the second cavity, and at the same time perform the second welding to complete the enclosure of the second cavity and connect the two cavities into one body to form the main structure of the roll-formed profile; S3. Adjust the arc radius of the roll-formed profile according to the required arc requirement for roll-arc forming; S4. Cut and下料 the roll-formed profile to a fixed length according to the required length to obtain a high energy-absorbing and lightweight roll-formed profile.

6. The method for processing a high energy absorption and lightweight roll-formed profile according to claim 5, characterized in that: The specific steps of step S2 are as follows: S21. Partial symmetric forming The profile enters the first cold roll forming unit, and firstly the inner top angles of the two cavities are symmetrically formed. Later, the bottom surface is reversed to control the rebound and avoid empty bending, so as to finish the forming of the inner top angles on both sides; then the outer top angles on both sides are symmetrically formed to a certain angle, and the bottom surface is kept in a reversed state, and the outer top angles on both sides are kept in a solid pressure state; then the outer top angle forming is suspended, and the bottom angles on both sides are symmetrically formed, and the bottom surface is kept in a reversed state, so that the outer bottom angles on both sides are always pressed to a certain angle, and finally the bottom surface is flattened, so that the high-precision symmetrical forming is completed; S22, molding of the first cavity The left bottom corner is formed quickly by multiple bending, and the left top corner is formed by multiple bending and springback control at the same time; then the right bottom corner is formed slowly, and the roller pressing space is reserved in the middle position through the forming speed difference on both sides to facilitate the closing of the first cavity; when the first cavity is closed, it enters the first welding mechanism for one welding to complete the closing of the first cavity; S23, molding of the second cavity The profile enters the second cold-bending forming unit, and is formed into the right bottom angle through multiple bending. At the same time, the right top angle is formed by multiple bending and springback control to complete the closure of the second cavity. When the second cavity is closed, it enters the second welding mechanism for secondary welding, and the second hook is welded to the lower wall to connect the two cavities into one, forming a closed roll-formed profile.

7. The method for processing a high energy absorption and lightweight roll-formed profile according to claim 6, characterized in that: When the double-layer reinforcement ribs are connected by hook welding, after the plate enters the first cold roll forming unit, the inverted V-shaped ribs of the bottom wall and the hooks at both ends of the plate are first symmetrically bent, and then the inner top angles of the two cavities are symmetrically formed after completion; When the double-layer reinforcement ribs are connected by hem welding, after the plate enters the first cold bending forming unit, the hems at both ends of the plate are first symmetrically bent, and then the inner top angles of the two cavities are symmetrically formed.

8. The method for processing a high energy absorption and lightweight roll-formed profile according to claim 7, characterized in that: The rolled profile obtained in step S23 is firstly passed through a sizing unit for more precise cross-sectional accuracy control, and then enters step S3.

9. The method for processing a high energy absorption and lightweight roll-formed profile according to claim 7, characterized in that: The primary welding and the secondary welding are arc welding or fusion welding; the arc welding is selected from tungsten inert gas shielded arc welding, metal inert gas shielded arc welding, carbon dioxide gas shielded arc welding or plasma arc welding, and the fusion welding is selected from electron beam welding or laser welding.

10. The use of the high energy absorption and lightweight roll-formed profile according to any one of claims 1 to 4, characterized in that: The rolled profile is used for producing automobile anti-collision beams, battery side beams or other side beam-type profiles.

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