Roll offset forming tool and method of mitigating distortion of sheet metal

Abstract

The roller offset forming tool includes a first roller configured to rotate in a first direction against the metal plate. The first roller includes a first deformation portion having a first shape. The tool includes a second roller disposed opposite the first roller and configured to engage the first roller. The second roller is configured to rotate against the metal sheet in a second direction opposite the first direction, thereby deforming the metal sheet and forming an offset feature therein. The second roller includes a secondary deformation having a second geometry. The first deformation portion is configured to align with and mate with the second deformation portion to hold the metal sheet between the first roller and the second roller. The first shape and the second geometry are configured to mitigate distortion of the metal plate in a region away from the offset feature and reinforce the metal plate at the offset feature.

Description

Technical Field

[0001] This disclosure relates to a roll offset forming tool and a method for reducing distortion in workpieces formed from sheet metal. Background Technology

[0002] Roller offset forming is a sheet metal manufacturing technique used to form complex three-dimensional (3D) sheet metal and shapes. The roller offset forming process uses a set of rollers moving along a predetermined path to bend and shape a flat sheet of metal into a desired 3D shape. As the rollers follow a manually or computer-controlled path, the set of rollers can apply bending forces to the sheet to produce plastic distortion. Although distortion may occur in the sheet in areas away from the roller's path, roller offset forming can be well-suited for prototyping and medium production volumes, and can potentially produce complex shapes with excellent dimensional accuracy and high geometric flexibility. Summary of the Invention

[0003] The roll offset forming tool includes a first roll configured to rotate against a metal sheet about a first longitudinal axis in a first direction. The first roll includes a first deformation portion having a first shape. The roll offset forming tool also includes a second roll disposed opposite to and configured to engage with the first roll. The second roll is configured to rotate against the metal sheet about a second longitudinal axis in a second direction opposite to the first direction, thereby distorting the metal sheet and forming an offset feature therein. The second roll includes a secondary deformation portion having a second geometry. The first deformation portion is configured to align and engage with the second deformation portion along a first vertical axis substantially perpendicular to both the first and second longitudinal axes, thereby holding the metal sheet between the first and second rolls. The first shape and the second geometry are configured to mitigate distortion of the metal sheet in regions away from the offset feature and to reinforce the metal sheet at the offset feature.

[0004] In one aspect, a first deformable portion may define a first channel therein, and a secondary deformable portion may be configured to protrude into the first channel along a first vertical axis.

[0005] On the other hand, each of the first deformation part and the secondary deformation part can be symmetrical across the first vertical axis.

[0006] In another respect, the first deformation part can be symmetrical across the first vertical axis, and the secondary deformation part can be asymmetrical across the first vertical axis.

[0007] In another embodiment, the first roller may further include a primary deformation portion spaced apart from the first deformation portion along a first longitudinal axis and having a first geometry. The second roller may further include a second deformation portion spaced apart from the secondary deformation portion along a second longitudinal axis and having a second shape. The first and second geometries may be configured to reduce distortion of the metal plate in regions away from the offset feature and to reinforce the metal plate at the offset feature.

[0008] In one aspect, the second deformation section may be configured to align and engage with the primary deformation section along a second vertical axis, the second vertical axis being spaced apart from the first vertical axis along a second longitudinal axis, thereby holding the metal plate between the first and second rollers.

[0009] On the other hand, the second deformation portion may define the second channel therein, and the primary deformation portion may be configured to protrude into the second channel.

[0010] On the other hand, the first deformation part may have a first radius, the primary deformation part may have a primary radius smaller than the first radius, the second deformation part may have a second radius, and the secondary deformation part may have a secondary radius smaller than the second radius.

[0011] In one aspect, the first roller may have a first distal end, and the second roller may have a second distal end aligned with the first distal end along a vertical axis substantially perpendicular to the first and second longitudinal axes. Furthermore, a primary knob may be positioned at a first distance from the first distal end, and a secondary knob may be positioned at a second distance from the second distal end, the second distance being between 20% and 80% of the first distance from the first distal end.

[0012] On the other hand, the first deformable portion and the second deformable portion can engage along a first vertical axis that is substantially perpendicular to the first longitudinal axis and the second longitudinal axis. Furthermore, the primary deformable portion and the second deformable portion can engage along a second vertical axis that is spaced apart from the first vertical axis along the second longitudinal axis.

[0013] In one aspect, a motor vehicle may include articles formed by a roll offset forming tool.

[0014] On the other hand, the roll offset forming system may include a metal plate sandwiched between a first deformation portion and a secondary deformation portion of the roll offset forming tool and configured to contact the first deformation portion and the secondary deformation portion of the roll offset forming tool.

[0015] On the other hand, the metal plate can be substantially free of distortion in areas spaced apart from the offset features.

[0016] In one embodiment, the roll offset forming tool includes a first roll configured to rotate against a metal sheet in a first direction. The first roll includes a first deformation portion and a primary deformation portion spaced apart from the first deformation portion and having a first geometry. The roll offset forming tool also includes a second roll disposed opposite to the first roll and configured to engage with the first roll. The second roll is configured to rotate against the metal sheet in a second direction opposite to the first direction, thereby deforming the metal sheet and forming an offset feature therein. The second roll includes a second deformation portion and a secondary deformation portion spaced apart from the second deformation portion and having a second geometry. The first geometry, the first shape, the second shape, and the second geometry are configured to mitigate distortion of the metal sheet in regions away from the offset feature and to reinforce the metal sheet at the offset feature. Each of the first shape and the second geometry includes a bottom fillet, a top fillet spaced apart from the bottom fillet, a top, a bottom spaced apart from the top, a sidewall connecting the top and the bottom, and an angle defined between the bottom and the sidewall. Furthermore, each of the first shape and the second geometry is defined by at least one of the following: a first set of variables, which includes a bottom fillet radius, a top fillet radius, a lower half width, an upper half width, and a deformable part height; and a second set of variables, which includes the bottom fillet radius, the top fillet radius, the tilt angle, the sidewall length, and the upper half width.

[0017] On the other hand, the first shape can depend on the second geometry.

[0018] In another respect, the first shape can be independent of the second geometry.

[0019] On the other hand, the tilt angle can be greater than 0° and less than or equal to 90°.

[0020] A method for mitigating workpiece distortion includes forming a workpiece with an offset feature and multiple regions from a sheet metal using a roll offset forming tool, each region being spaced apart from the offset feature. The roll offset forming tool includes a first roll configured to rotate against the sheet metal in a first direction about a first longitudinal axis. The first roll includes a first deformation portion having a first shape. The roll offset forming tool also includes a second roll disposed opposite to and configured to engage with the first roll. The second roll is configured to rotate against the sheet metal in a second direction opposite to the first direction about a second longitudinal axis, thereby deforming the sheet metal and forming the offset feature therein. The second roll includes a secondary deformation portion having a second geometry. The first deformation portion is configured to align and engage with the second deformation portion along a first vertical axis substantially perpendicular to both the first and second longitudinal axes, thereby holding the sheet metal between the first and second rolls. The first shape and the second geometry are configured to mitigate distortion of the sheet metal in regions away from the offset feature and to reinforce the sheet metal at the offset feature. The method also includes measuring the height (h) of the offset feature. o ) and the actual height (h) of each of the multiple areas. i The method involves assigning a distortion value (DDV) to the workpiece. Furthermore, the method includes determining whether the distortion value (DDV) is less than or equal to a threshold distortion value (DDV). t If the distortion value (DDV) is greater than the threshold distortion value (DDV) t The method involves altering at least one of a first shape and a second geometry to form a subsequent workpiece. If the distortion value (DDV) is less than or equal to a threshold distortion value (DDV)... t If the method involves forming a subsequent workpiece without altering at least one of the first shape and the second geometry, thereby mitigating workpiece distortion.

[0021] In one aspect, the allocation may include calculating the distortion value (DDV) according to formula (I):

[0022] (I)DDV = root mean square (h i –h)

[0023] Where: hi is the actual height of one of the multiple regions, and h is the ideal height of any distortion and less than the height of the offset feature (h0), such that when (h i When –h) is close to zero, the distortion of the workpiece can be reduced.

[0024] On the other hand, forming may include sandwiching a metal plate between a first deformation portion and a secondary deformation portion.

[0025] On the other hand, the formation may include rotating a first roller against a metal plate in a first direction and rotating a second roller against a metal plate in a second direction, such that the primary deformation section distorts the metal plate at the secondary deformation section, thereby forming an offset feature.

[0026] The foregoing features and advantages, as well as other features and accompanying advantages, will become apparent when taken in conjunction with the accompanying drawings and the appended claims, based on the following detailed description of illustrative examples and models used to carry out this disclosure. Furthermore, this disclosure expressly includes combinations and sub-combinations of the elements and features presented above and below. Attached Figure Description

[0027] Figure 1 This is a schematic side view of a roll offset forming tool, which includes a first roll spaced apart from a second roll.

[0028] Figure 2 yes Figure 1 A schematic side view of the first deformation section, primary deformation section, second deformation section and secondary deformation section of the roller offset forming tool.

[0029] Figure 3A It is limited by the first set of variables. Figure 1 and Figure 2 A schematic outline of a portion of another embodiment of the first roller.

[0030] Figure 3B It is limited by the second set of variables. Figure 1 and Figure 2 A schematic outline of a portion of another embodiment of the second roller.

[0031] Figure 4 yes Figure 1 and Figure 2 A schematic outline of a portion of the first and second rollers.

[0032] Figure 5 It includes Figure 1 and Figure 2 A schematic side view of the roller offset forming system of the roller offset forming tool.

[0033] Figure 6 It includes by Figure 1 and Figure 2 A schematic top view of a workpiece with offset features formed by an offset forming tool.

[0034] Figure 7 It includes by Figure 1 and Figure 2 A schematic perspective view of a motor vehicle product formed by a roller offset forming tool.

[0035] Figure 8It is to alleviate the Figure 1 and Figure 2 A schematic flowchart of a method for distorting a workpiece formed by a roller offset forming tool.

[0036] Figure 9 yes Figure 6 A schematic perspective view of the workpiece.

[0037] Figure 10 yes Figure 9 A schematic side view of the workpiece. Detailed Implementation

[0038] Referring to the accompanying drawings, where the same reference numerals denote the same elements, the roller offset forming tool 10 is generally shown. Figure 1 and Figure 2 ) and lightening by metal plate 18 ( Figure 5 ) formed workpiece 16 ( Figure 9 Aberration 14 in ) Figure 10 Method 12 Figure 8 The roller offset forming tool 10 and method 12 can be used to form a shape from a metal sheet 18 and include an offset feature 22. Figure 6 20 three-dimensional artifacts Figure 7 Applications of this technology. Specifically, the roll offset forming tool 10 and method 12 can be used to induce one or more offset features 22 or bends in the sheet metal 18 without affecting the region 24 spaced apart from the offset features 22. Figure 6 and Figure 9 Undesirable distortions are generated in )14.

[0039] More specifically, the roller offset forming tool 10 and method 12 use a custom set of rollers 26, 28 ( Figure 1 ) forming offset feature 22, the customized set of rollers including first deformation section 42 ( Figure 1 ) and secondary deformation part 32 ( Figure 1 The first deformation section 42 and the secondary deformation section 32 are configured to cause deformation of the metal sheet 18, increasing the stiffness of the metal sheet 18 at the offset feature 22 and controlling the distortion 14 in the region 24 away from the offset feature 22. The set of rollers 26, 28 can be customized with the first deformation section 42 and the secondary deformation section 32 to avoid additional tooling input and ensure excellent dimensional accuracy of the offset feature 22 and the stiffness of the formed workpiece 16. Therefore, the roller offset forming tool 10 and method 12 enable the production of articles 20 with complex shapes and excellent dimensional accuracy without excessive distortion 14.

[0040] Therefore, the roll offset forming tool 10 and method 12 can be used in automotive applications, such as, but not limited to, prototyping and manufacturing articles 20, such as shearing plates, slides, pipes, brackets, linear guides, tools, assembly aids, and other vehicle parts. For example, motor vehicles 34 ( Figure 7 The method may include an article 20 formed by the roll offset forming tool 10 and method 12, such as a shearing plate for a battery. Alternatively, the roll offset forming tool 10 and method 12 may be used for non-automotive applications, such as, but not limited to, prototyping and manufacturing articles 20 and parts for aerospace, aviation, marine, transportation, robotics, construction, industrial, medical and consumer product applications.

[0041] Now for reference Figure 1 and Figure 2 The roller offset forming tool 10 includes a first roller 26 configured to rotate against a metal plate 18 about a first longitudinal axis 62 in a first direction 36. Figure 5 The roll offset forming tool 10 also includes a second roll 28 disposed opposite to and configured to engage with the first roll 26. The second roll 28 is configured to rotate against the metal sheet 18 in a second direction 38 opposite to the first direction 36 about a second longitudinal axis 64, thereby deforming the metal sheet 18 and forming an offset feature 22 therein. For example, the first roll 26 and the second roll 28 may be annular and may be configured to hold the metal sheet 18 therebetween during the roll offset forming process. In a non-limiting example, the first roll 26 may be configured as a punch and the second roll 28 may be configured as a die.

[0042] like Figure 1 and Figure 2 As shown in the best embodiment, the first roller 26 includes a first shape 122 ( Figure 1 The first deformable portion 42 of the roller 26. Similarly, the second roller 26 includes a second geometry 48. Figure 1 The secondary deformation section 32. The first deformation section 42 is configured along a first vertical axis 80 that is substantially perpendicular to the first longitudinal axis 62 and the second longitudinal axis 64. Figure 2 It is aligned and engaged with the secondary deformation section 32, thereby holding the metal plate 18 between the first roller 26 and the second roller 28.

[0043] Continue to refer to Figure 2 In another embodiment described, the first roller 26 may further include a primary deformation portion 30 spaced apart from the first deformation portion 42 along the first longitudinal axis 62 and having a first geometry 44. It should be noted that the first deformation portion 42 and the primary deformation portion 30 do not necessarily have the same shape or form. That is, the first deformation portion 42 and the primary deformation portion 30 may have different shapes. First shape 122 ( Figure 1The first deformable part 42 is used in this document to describe the first geometric structure 44. Figure 1 The term 30 is used herein to describe the primary deformation section. Similarly, the second roller 28 may also include sections spaced apart from the secondary deformation section 32 and having a second shape 124. Figure 1 The second deformable portion 46. For clarity, the second deformable portion 46 and the secondary deformable portion 32 do not necessarily have the same shape or form. That is, the second deformable portion 46 and the secondary deformable portion 32 can have different shapes. The second shape 124 is used herein to describe the second deformable portion 46, and the second geometry 48 is used herein to describe the secondary deformable portion 32.

[0044] As described in more detail below, the first shape 122 and the second geometry 48 are configured to reduce the weight of the metal plate 18 in addition to the offset feature 22. Figure 6 Area 24 outside of ) Figure 6 and Figure 9 The distortion 14 in the metal plate 18 is mitigated, and the metal plate 18 is reinforced at the offset feature 22. Furthermore, for embodiments including two sets of deformable portions (i.e., a first deformable portion 42, a secondary deformable portion 32, a second deformable portion 46, and a primary deformable portion 30), the first geometry 44 and the second geometry 48, as well as the first shape 122 and the second shape 124, can be configured to reduce the distortion 14 of the metal plate 18 in the region 24 away from the offset feature 22, and to reinforce the metal plate 18 at the offset feature 22. Specifically, referring to… Figure 1 The offset feature 22 itself can be formed due to the tilt offset of the first roller 26 and the second roller 28, for example, on the ramp or inclined surface 126 between the first deformed portion 42 and the primary deformed portion 30. Figure 1 At that location, the corresponding slope or inclined surface 226 between the slope or inclined surface 126 and the second deformed part 46 and the secondary deformed part 32. Figure 1 Pairing. However, the first shape 122 and the second geometry 48 can control and / or minimize distortion 14 in the region 24 away from the offset feature 22. More specifically, the first shape 122 and the second geometry 48 can form a surrounding feature around the offset feature 22 and minimize distortion away from the offset feature 22. That is, for an embodiment including two pairs of deformable portions 42-32, 46-30, based on the first geometry 44 of the primary deformable portion 30 and the second geometry 48 of the secondary deformable portion 32, combined with the first shape 122 and the second shape 124 of the first deformable portion 42 and the second deformable portion 46 respectively, the metal plate 18 can be substantially free of distortion 14 in the region 24 spaced apart from the offset feature 22.

[0045] If you continue to refer to Figure 2Each of the first deformable portion 42, the primary deformable portion 30, the second deformable portion 46, and the secondary deformable portion 32 may be annular and may protrude radially from or be recessed toward the respective centers of the first roller 26 and the second roller 28. The primary deformable portion 30 may be relatively smaller than the first deformable portion 42, and the secondary deformable portion 32 may be relatively smaller than the second deformable portion 46. That is, the first deformable portion 42 may have a first radius 50, and the primary deformable portion 30 may have a primary radius 52 smaller than the first radius 50. Similarly, the second deformable portion 46 may have a second radius 54, and the secondary deformable portion 32 may have a secondary radius 56 smaller than the second radius 54. The first deformable portion 42, the primary deformable portion 30, the second deformable portion 46, and the secondary deformable portion 32 may be referred to as miniature deformable portions because the deformable portions 42, 30, 46, and 32 may be smaller than the total dimensions of the corresponding first roller 26 and second roller 28. In other words, the step length or height of the protrusions of the primary deformation portion 30 and the secondary deformation portion 32, as well as the step length or depth of the recesses of the first deformation portion 42 and the second deformation portion 46, can be relatively smaller than the total dimensions of the first roller 26 and the second roller 28, respectively. The micro-deformation portions 42, 30, 46, and 32 can be shaped to cause additional deformation of the metal plate 18, forming an offset feature 22, reinforcing the metal plate 18 at the offset feature 22, and reducing the distortion 14 of the metal plate 18 in the region 24 away from the offset feature 22.

[0046] In particular, and as will continue to refer to Figure 2 During the roll offset forming operation, the first deformation portion 42 can be configured to align with the secondary deformation portion 32, and the second deformation portion 46 can be configured to align with the primary deformation portion 30, thereby holding the metal sheet 18 between the first roller 26 and the second roller 28. The first deformation portion 42 can define a first channel 58, a recess, or a depression therein, and the second deformation portion 46 can define a second channel 60, a recess, or a depression therein. That is, the first shape 122 can be the first channel 58, and the second shape 124 can be the second channel 60. The primary deformation portion 30 can be configured to protrude into the second channel 60, and the secondary deformation portion 32 can be configured to protrude into the first channel 58. In this way, the first roller 26 and the second roller 28 can engage at the mating point of the first deformation portion 42 and the secondary deformation portion 32 and at the mating point of the second deformation portion 46 and the primary deformation portion 30, thereby holding the metal sheet 18 therein. When the first roller 26 is along the first direction 36 ( Figure 1 ) rotates and the second roller 28 rotates in a second direction 38 opposite to the first direction 36. Figure 1 When rotating, the roller offset forming tool 10 can form an offset feature 22 in the metal plate 18.

[0047] More details and refer again Figure 2The first roller 26 may have a first longitudinal axis 62, and the primary deformation portion 30 may be spaced apart from the first roller 26 along the first longitudinal axis 62. Additionally, the second roller 28 may have a second longitudinal axis 64, and the secondary deformation portion 32 may be spaced apart from the second deformation portion 46 along the second longitudinal axis 64. That is, the first roller 26 may have a first distal end 66, and the second roller 28 may have a second distal end 68, which is aligned with the first distal end 66 along a vertical axis 70, which is substantially perpendicular to the first longitudinal axis 62 and the second longitudinal axis 64. The primary deformation portion 30 may be disposed at a first distance 72 from the first distal end 66, and the secondary deformation portion 32 may be disposed at a second distance 74 from the second distal end 68. The second distance 74 may be 20% to 80% of the first distance 72, for example, 25% to 75% of the first distance 72, or 50% to 65% of the first distance 72.

[0048] In addition, as referenced Figure 2 The first deformable portion 42 may have a first surface width 76 along the first longitudinal axis 62, and the secondary deformable portion 32 may be positioned along the second longitudinal axis 64 to be aligned with the first deformable portion 42 within the dimension of the first surface width 76. Similarly, the second deformable portion 46 may have a second surface width 78 along the second longitudinal axis 64, and the primary deformable portion 30 may be positioned along the first longitudinal axis 62 to be aligned with the second deformable portion 46 within the dimension of the second surface width 78. Therefore, the acceptable positioning of the primary deformable portion 30 and the secondary deformable portion 32 can be selected and optimized within the constraints of the second surface width 78 and the first surface width 76, respectively.

[0049] Continue to refer to Figure 2 The first deformation portion 42 and the secondary deformation portion 32 can be aligned and engaged along the first vertical axis 80, which is substantially perpendicular to the first longitudinal axis 62 and the second longitudinal axis 64. Similarly, the second deformation portion 46 can be configured to align and engage with the primary deformation portion 30 along the second vertical axis 82, which is spaced apart from the first vertical axis 80 along the second longitudinal axis 64, thereby holding the metal plate 18 between the first roller 26 and the second roller 28. That is, the primary deformation portion 30 and the second deformation portion 46 can be aligned and engaged along the second vertical axis 82, which is spaced apart from the first vertical axis 80 along the second longitudinal axis 64.

[0050] Now for reference Figure 5In a non-limiting example, each of the first deformable portion 42 and the secondary deformable portion 32 may be symmetrical across the first vertical axis 80. That is, the first shape 122 of the first deformable portion 42 may match the second geometry 48 of the secondary deformable portion 32. Additionally or alternatively, each of the second deformable portion 46 and the primary deformable portion 30 may be symmetrical across the second vertical axis 82. That is, the second shape 124 of the second deformable portion 46 may match the first geometry 44 of the primary deformable portion 30.

[0051] However, reference Figure 4 In another non-limiting example, the first deformable portion 42 may be symmetrical across the first vertical axis 80, and the secondary deformable portion 32 may be asymmetrical across the first vertical axis 80. That is, the first shape 122 of the first deformable portion 42 may not match the second geometry 48 of the secondary deformable portion 32. Additionally or alternatively, although not shown, the second deformable portion 46 may be symmetrical across the second vertical axis 82, and the primary deformable portion 30 may be asymmetrical across the second vertical axis 82. That is, the second shape 124 of the second deformable portion 46 may not match the first geometry 44 of the primary deformable portion 30.

[0052] Now for reference Figure 3A and 3B In another embodiment, each of the first shape 122 and the second geometry 48 includes a bottom fillet 84, a top fillet 86 spaced apart from the bottom fillet 84, a top 88, a bottom 90 spaced apart from the top 88, a sidewall 92 connecting the top 88 and the bottom 90, and a tilt angle 94 defined between the bottom 90 and the sidewall 92. The tilt angle 94 can be greater than 0 and less than or equal to 90 degrees, such that the offset feature 22 can gradually transition between the bottom 90 and the sidewall 92.

[0053] In this embodiment, each of the first shape 122 and the second geometry 48 is determined by the first variable group 96 ( Figure 3A ) and the second variable group 98 ( Figure 3B At least one of the following is defined: The first variable group 96 includes a bottom fillet radius of 100, a top fillet radius of 102, a lower half width of 104, an upper half width of 106, and a deformation height of 108. The second variable group 98 includes a bottom fillet radius of 100, a top fillet radius of 102, a tilt angle of 94, a sidewall height length of 110, and an upper half width of 106.

[0054] The first set of variables 96 and / or the second set of variables 98 can be iteratively optimized, for example, based on feedback loops of Gaussian process regression and Bayesian optimization, as well as finite element analysis, to provide a first shape 122 of the first deformable part 42 and a second geometry 48 of the secondary deformable part 32. Furthermore, design criteria and parameters based on the first set of variables 96 can be correlated with and converted to design criteria and parameters based on the second set of variables 98.

[0055] For example, using a first variable group 96 or a second variable group 98 of five independent variables, each side of the first deformable portion 42 across the first vertical axis 80 and each side of the secondary deformable portion 32 across the first vertical axis 80 can be parameterized to define the corresponding first shape 122 and second geometry 48 of the deformable portions 42, 32. Symmetrical design of the two sides of the first deformable portion 42 and the two sides of the secondary deformable portion 32 may not be necessary. However, for asymmetrical designs, the two sides of the first deformable portion 42 and / or the secondary deformable portion 32 can be defined by the first variable group 96 and / or the second variable group 98. Furthermore, each side of the second deformable portion 46 across the second vertical axis 82 and each side of the primary deformable portion 30 across the second vertical axis 82 can be parameterized to define the corresponding second shape 124 and first geometry 44 of the deformable portions 46, 30. Symmetrical design of the two sides of the second deformable portion 46 and the two sides of the primary deformable portion 30 may not be necessary. However, for asymmetrical designs, the two sides of the second deformation section 46 and / or the primary deformation section 30 may be defined by the first variable group 96 and / or the second variable group 98.

[0056] Furthermore, the first shape 122 of the first deformable portion 42 and the second geometric structure 48 of the secondary deformable portion 32 can be identified independently or dependently. That is, the first shape 122 of the first deformable portion 42 may depend on the second geometric structure 48 of the secondary deformable portion 32. Alternatively, the first shape 122 of the first deformable portion 42 may be independent of the second geometric structure 48 of the secondary deformable portion 32. Similarly, the second shape 124 of the second deformable portion 46 and the first geometric structure 44 of the primary deformable portion 30 can be identified independently or dependently. That is, the second shape 124 of the second deformable portion 46 may depend on the first geometric structure 44 of the primary deformable portion 30. Alternatively, the second shape 124 of the second deformable portion 46 may be independent of the first geometric structure 44 of the primary deformable portion 30. Likewise, the first shape 122 of the first deformable portion 42 and the second shape 124 of the second deformable portion 46 can be identified independently or dependently. That is, the first shape 122 of the first deformable portion 42 may depend on the second shape 124 of the second deformable portion 46. Alternatively, the first shape 122 of the first deformable portion 42 can be independent of the second shape 124 of the second deformable portion 46. Similarly, the first geometry 44 of the primary deformable portion 30 and the second geometry 48 of the secondary deformable portion 32 can be identified independently or dependently. That is, the first geometry 44 of the primary deformable portion 30 can depend on the second geometry 48 of the secondary deformable portion 32. Alternatively, the first geometry 44 of the primary deformable portion 30 can be independent of the second geometry 48 of the secondary deformable portion 32.

[0057] exist Figure 3A and Figure 3B In a best-illustrative, non-limiting example, the first shape 122 may depend on the second geometry 48. That is, the design of the first shape 122 may depend on the design of the second geometry 48. Figure 4 In another non-limiting example best illustrated, the first shape 122 can be independent of the second geometry 48. That is, the design of the first shape 122 and the second geometry 48 can be independent of each other.

[0058] The first shape 122 and the second shape 124, as well as the first geometry 44 and the second geometry 48, may also be constrained by other considerations, such as the manufacturing feasibility of the first roller 26 and its associated deformable portions 30, 42, and the second roller 28 and its associated deformable portions 32, 46. For example, refer to Figure 3A and 3B For some applications, the bottom corner radius 100 and the top corner radius 102 can be constrained by minimum values. Similarly, the lower half width 104 can be greater than or equal to the upper half width 106.

[0059] Furthermore, although the roller offset forming tool 10 is described herein as including at least one beadpair, namely a first deformable portion 42 and a secondary deformable portion 32, or in some embodiments including at least two deformable portion beadpairs, namely additionally including a primary deformable portion 30 and a second deformable portion 46, the roller offset forming tool 10 may include more than four deformable portions or two pairs of deformable portions depending on the desired characteristics and position of the offset feature 22. For example, although not shown, the first roller 26 may include a third deformable portion and tertiary deformable portions spaced apart from the third deformable portion. Similarly, as a non-limiting example, the second roller 28 may include a fourth deformable portion and quaternary deformable portions spaced apart from the fourth deformable portion. The third deformable portion may be configured to align with the quaternary deformable portion, and the fourth deformable portion may be configured to align with the tertiary deformable portion.

[0060] Advantageously, the roll offset forming tool 10 mitigates the distortion 14 of the workpiece 16 in the region 24 far from the offset feature 22 by allowing optimized first roll 26 and second roll 28 to be set at a calculated position according to the desired offset feature 22 and the desired stiffness of the workpiece 16, while optimizing the stiffness of the workpiece 16. The optimized first roll 26 and second roll 28 include one or more micro-deformation portions, such as a first deformation portion 42 and a secondary deformation portion 32.

[0061] Now for reference Figure 5 The roll offset forming system 40 may include a metal plate 18 sandwiched between and in contact with a first deformation portion 42 and a secondary deformation portion 32 of the roll offset forming tool 10. Similarly, the roll offset forming system 40 may also include a metal plate 18 sandwiched between and in contact with a primary deformation portion 30 and a second deformation portion 46 of the roll offset forming tool 10. Depending on the application or end use of the workpiece 16, the metal plate 18 may be formed from any suitable metal. In a non-limiting example, the metal plate 18 may be formed from an aluminum alloy such as AA5754-O and may be 1 mm to 1.5 mm thick.

[0062] Now for reference Figure 8 The method 12 for reducing the distortion 14 of workpiece 16 includes forming (112) a region 24 with offset features 22 and multiple areas 24 from metal sheet 18 using a roller offset forming tool 10. Figure 9The workpiece 16, each region 24 is spaced apart from the offset feature 22. That is, the formation (112) may include clamping the metal plate 18 between at least the first deformation portion 42 and the secondary deformation portion 32, and in some embodiments, as described above, additionally between the second deformation portion 46 and the primary deformation portion 30. Furthermore, the formation (112) may include rotating the first roller 26 against the metal plate 18 in a first direction 36 and rotating the second roller 28 against the metal plate 18 in a second direction 38, such that the first deformation portion 42 deforms the metal plate 18 at the secondary deformation portion 32, thereby forming the offset feature 22.

[0063] Although offset feature 22 is in Figure 9 and Figure 10 The offset feature 22 is shown as a roughly rectangular or stadium-shaped structure, but it can have any desired shape depending on the selected first shape 122 and second geometry 48, or additional first geometry 44 and second shape 124. That is, the depth, width, and other geometric features of the offset feature 22 can be changed by adjusting the relative positions of the first roller 26 and the second roller 28, and by changing the first shape 122 and second geometry 48 of the first deformation section 32 and the secondary deformation section 32, the second shape 124 of the second deformation section 46, and the first geometry 44 of the primary deformation section 30, respectively. Each of the plurality of regions 24 can be spaced apart from the offset feature 22, and, as a non-limiting example, can be located in one or more of the corners of the metal plate 18, at the edges of the metal plate 18, in the central region of the metal plate 18, and in the eccentric regions of the metal plate 18.

[0064] Refer again Figure 8 And as referenced Figure 9 and Figure 10 As best described, method 12 also includes measuring the height (h) of offset feature 22. o ) and the actual height (h) of each of the multiple regions 24 i Method 12 also includes assigning a distortion degree value (DDV) to workpiece 16 (116). For example, assigning 116 may include calculating the distortion degree value (DDV) according to formula (I):

[0065] DDV = Root Mean Square (h) i -h)

[0066] Where h i h is the actual height of one of the multiple regions 24, and h is the ideal height of any distortion 14 and less than the height of the offset feature 22 (h o ), such that when (h iWhen h approaches zero, the distortion 14 of the workpiece 16 is reduced. For example, h may correspond to the tolerance of the distortion 14 in the workpiece 16 formed by the metal plate 18, such as 0 mm to 5 mm, or 0.5 mm to 3 mm, or 1 mm to 2 mm.

[0067] Method 12 also includes determining (118) whether the distortion value (DDV) is less than or equal to the threshold distortion value (DDV). t Threshold distortion value (DDV) t It can be set according to the tolerance of distortion 14 in workpiece 16, and can depend on the end use of workpiece 16 or product 20.

[0068] Refer again Figure 8 If the distortion value (DDV) is greater than the threshold distortion value (DDV) t If the distortion value (DDV) is less than or equal to the threshold distortion value (DDV), then method 12 includes changing (120) at least one of the first shape 122 and the second geometry 48 and forming (112) the subsequent workpiece 16. That is, method 12 may include selecting at least one of the first shape 122 and the second geometry 48 before forming another workpiece 16. t If the distortion 14 of the workpiece 16 is reduced, then method 12 includes forming (112) a subsequent workpiece 16 without changing at least one of the first shape 122 and the second geometry 48 (120). That is, if the distortion degree value (DDV) is less than or equal to the threshold distortion degree value (DDVt), the first shape 122 and / or the second geometry 48 are optimized to produce an offset feature 22, such that the distortion 14 in the region 24 far from the offset feature 22 can be reduced.

[0069] Advantageously, method 12 allows for quantification of distortion 14 and incremental design changes to the first shape 122 of the first deformed portion 42 and the second geometry 48 of the secondary deformed portion 32, and in some embodiments, also allows for incremental design changes to the first geometry 44 of the primary deformed portion 30 and the second shape 124 of the second deformed portion 46. That is, method 12 uses at least parameterized first shape 122 and parameterized second geometry 48 to achieve a final reduction of distortion 14 in the metal plate 18.

[0070] Therefore, method 12 and the roll offset forming tool 10 are capable of producing smoothly curved panels from a flat metal sheet 18 with high dimensional accuracy. The roll offset forming tool 10 and method 12 can be used with a first deformation section 42 (for inducing deformation of the metal sheet 18) Figure 1 ) and secondary deformation part 32 ( Figure 1 A set of rollers 26 and 28 Figure 1The offset feature 22 is formed, increasing the stiffness of the metal plate 18 at the offset feature 22 and controlling the distortion 14 in the region 24 away from the offset feature 22, all without additional tooling input. Therefore, the roll offset forming tool 10 and method 12 enable the production of articles 20 with complex shapes and excellent dimensional accuracy without excessive distortion 14.

[0071] The embodiments described in this disclosure are intended as non-limiting examples, and other embodiments may take various and alternative forms. Additionally, the drawings are not necessarily drawn to scale and may present slightly simplified representations of various features of this disclosure, including, for example, particular dimensions, orientations, positions, and shapes. Details associated with these features will be determined in part by the intended application and usage environment of the described embodiments.

[0072] For the purposes of this specification, unless specifically excluded, the use of the singular includes the plural, and vice versa; the terms “and” and “or” should be connected and separate; and the words “including,” “containing,” “comprising,” “having,” etc., should mean “including but not limited to.” Furthermore, approximate words such as “about,” “substantially,” “approximately,” etc., may be used herein in the sense of “at,” “near,” or “within 0-5% of,” or “within acceptable manufacturing tolerances,” or logical combinations thereof. As used herein, a component “configured” to perform the specified function is capable of performing the specified function without alteration, rather than merely having the potential to perform the specified function after further modification. In other words, when the described hardware is explicitly configured to perform the specified function, the described hardware is specifically selected, created, implemented, utilized, programmed, and / or designed to perform the specified function. Additionally, the use of ordinal numbers such as first, second, and third does not necessarily imply a sense of sequential order, but may simply distinguish multiple instances of an action or structure.

[0073] The detailed description and accompanying drawings are intended to support and describe this teaching, but the scope of this teaching is defined only by the claims. While some best modes and other embodiments for carrying out this teaching have been described in detail, various alternative designs and embodiments exist for practicing the teaching as defined in the appended claims. Furthermore, this disclosure expressly includes combinations and sub-combinations of the elements and features presented above and below.

Claims

1. A roller offset forming tool, comprising: A first roller, configured to rotate about a first longitudinal axis against a metal plate in a first direction; The first roller includes a first deformable portion having a first shape; as well as The second roller is disposed opposite to the first roller and is configured to engage with the first roller; The second roller is configured to rotate against the metal plate in a second direction opposite to the first direction about a second longitudinal axis, thereby deforming the metal plate and forming an offset feature therein; The second roller includes a secondary deformation section having a second geometric structure; The first deformation portion is configured to align and engage with the secondary deformation portion along a first vertical axis substantially perpendicular to the first longitudinal axis and the second longitudinal axis, thereby holding the metal plate between the first roller and the second roller; The first shape and the second geometry are configured to reduce distortion of the metal plate in regions away from the offset feature and to reinforce the metal plate at the offset feature.

2. The roller offset forming tool according to claim 1, wherein: The first deformable portion defines a first channel therein; and The secondary deformation portion is configured to protrude into the first channel along the first vertical axis.

3. The roller offset forming tool according to claim 1, wherein, Each of the first deformation portion and the secondary deformation portion is symmetrical across the first vertical axis.

4. The roller offset forming tool according to claim 1, wherein, The first deformation portion is symmetrical across the first vertical axis, and the secondary deformation portion is asymmetrical across the first vertical axis.

5. The roller offset forming tool according to claim 1, wherein: The first roller further includes a primary deformation section, which is spaced apart from the first deformation section along the first longitudinal axis and has a first geometric structure; and The second roller further includes a second deformation section, which is spaced apart from the secondary deformation section along the second longitudinal axis and has a second shape; The first and second geometries are configured to reduce distortion of the metal plate in regions away from the offset feature and to reinforce the metal plate at the offset feature.

6. The roller offset forming tool according to claim 5, wherein, The second deformation section is configured to align and engage with the primary deformation section along a second vertical axis, the second vertical axis being spaced apart from the first vertical axis along the second longitudinal axis, thereby holding the metal plate between the first roller and the second roller.

7. The roller offset forming tool according to claim 5, wherein: The second deformable part defines the second channel therein; as well as The primary deformation section is constructed to protrude into the second channel.

8. The roller offset forming tool according to claim 5, wherein: The first roller has a first distal end; The second roller has a second distal end aligned with the first distal end along a vertical axis, the vertical axis being substantially perpendicular to the first longitudinal axis and the second longitudinal axis; The primary deformation section is located at a first distance from the first distal end; The secondary deformation section is disposed at a second distance from the second distal end; and The second distance is 20% to 80% of the first distance from the first farthest point.

9. A method for reducing workpiece distortion, the method comprising: A workpiece having an offset feature and multiple regions is formed from a metal sheet using a roll offset forming tool, wherein each of the multiple regions is spaced apart from the offset feature, and wherein the roll offset forming tool comprises: A first roller, configured to rotate about a first longitudinal axis against a metal plate in a first direction; The first roller includes a first deformable portion having a first shape; and The second roller is disposed opposite to the first roller and is configured to engage with the first roller; The second roller is configured to rotate against the metal plate in a second direction opposite to the first direction about a second longitudinal axis, thereby deforming the metal plate and forming an offset feature therein; The second roller includes a secondary deformation section having a second geometric structure; The first deformation portion is configured to align and engage with the secondary deformation portion along a first vertical axis substantially perpendicular to the first longitudinal axis and the second longitudinal axis, thereby holding the metal plate between the first roller and the second roller; The first shape and the second geometry are configured to reduce the distortion of the metal plate in a region away from the offset feature and to reinforce the metal plate at the offset feature; Measure the height (h) of the offset feature o ) and the actual height (h) of each of the multiple regions. i ); Assign a distortion value (DDV) to the workpiece; Determine whether the distortion value (DDV) is less than or equal to the threshold distortion value (DDV). t ); If the distortion value (DDV) is greater than the threshold distortion value (DDV) t If the first shape and the second geometry are altered, at least one of them is changed to form a subsequent workpiece; and If the distortion value (DDV) is less than or equal to the threshold distortion value (DDV) t If the first shape and at least one of the second geometry are not changed, the subsequent workpiece is formed, thereby reducing the distortion of the workpiece.

10. The method according to claim 9, wherein, The allocation includes calculating the distortion value (DDV) according to formula (I): (I)DDV = root mean square (h i –h) in: h i It is the actual height of one of the multiple regions; and h is the ideal height for any distortion and is less than the height of the offset feature (h). o ), such that when (h i When –h) approaches zero, the distortion of the workpiece is reduced.

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