Rolling forming process and rolling forming equipment

Abstract

The invention discloses a rolling forming process and rolling forming equipment. The rolling forming process comprises the steps that primary rolling is conducted, specifically, an acute included angle between an area of the first side of a datum plane of a workpiece and the datum plane is rolled to be a first preset angle, and an acute included angle between the area of the second side of the datum plane and the datum plane is rolled to be a second preset angle; rotating the workpiece for the first time and inclining the workpiece; secondary rolling is conducted, specifically, rolling is conducted on the areas on the two sides of the datum plane on the inclined workpiece; the workpiece is rotated for the second time, the workpiece continues to be inclined, and the area of the second side of the reference plane continues to be rolled; and rotating the workpiece for three times, reversely inclining the workpiece, and rolling the area on the second side of the reference plane to reduce the included angle between the area and the reference plane. In the production process of the rolling piece, the workpiece is rolled step by step, the gradient of the reference plane of the workpiece is adjusted by inclining the workpiece, then the bending fillet of the workpiece can be rolled through the main roller, a cantilever inclined roller does not need to be used, and the production cost of the rolling piece is reduced.

Description

Technical Field

[0001] This application relates to the field of vehicle manufacturing technology, and in particular to a roll forming process and roll forming equipment. Background Technology

[0002] Roll forming is an important process in the production of automotive parts. It uses a series of sequentially arranged forming rolls to continuously bend metal sheets and strips laterally to form profiles with specific cross-sections. In addition to the main rolls, current roll forming processes often use cantilevered skew rolls as auxiliary rolls to compensate for the springback of parts caused by bending angles. However, due to their extended structure and inclined setting, the processing, installation, and debugging of cantilevered skew rolls are more complex than those of main rolls, resulting in higher production and maintenance costs and thus increasing the manufacturing cost of roll-formed parts.

[0003] Therefore, how to reduce the production cost of roll forming parts is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0004] In view of this, the purpose of this application is to provide a roll forming process and roll forming equipment to reduce the production cost of roll forming parts.

[0005] To achieve the above objectives, this application provides the following technical solution:

[0006] A roll forming process includes at least the following steps:

[0007] In the primary rolling process, a reference plane is positioned in the middle area of ​​the workpiece. The workpiece structure on both sides of the reference plane is gradually rolled through multiple rolling equipment. The acute angle between the workpiece on the first side of the reference plane and the reference plane is the first preset angle, and the acute angle between the workpiece on the second side of the reference plane and the reference plane is the second preset angle. The reference plane remains horizontal during the primary rolling process.

[0008] Rotate the workpiece once to tilt it so that the reference plane forms an acute angle with the horizontal direction at a third preset angle.

[0009] Two-stage rolling is used to roll the workpieces on both sides of the reference plane; the angle between the workpiece on the first side of the reference plane and the reference plane is reduced from a first preset angle to a fourth preset angle during rolling, and the angle between the workpiece on the second side of the reference plane and the reference plane is increased from a second preset angle to a fifth preset angle during rolling.

[0010] The workpiece is rotated twice and tilted in the same direction. The acute angle between the reference plane and the horizontal direction increases from the third preset angle to the sixth preset angle. The angle between the workpiece on the second side of the reference plane and the reference plane increases from the fifth preset angle to the seventh preset angle.

[0011] The workpiece is rotated three times and tilted in the opposite direction. The acute angle between the reference plane and the horizontal direction is reduced from the sixth preset angle to the eighth preset angle. The angle between the workpiece on the second side of the reference plane and the reference plane is rolled from the seventh preset angle to the finished product angle.

[0012] Preferably, in the above-mentioned roll forming process, the second workpiece rotation step is performed at least twice between the first workpiece rotation step and the third workpiece rotation step.

[0013] Preferably, in the above-mentioned roll forming process, in the primary roll forming step, the workpieces on both sides of the reference plane are further formed with height features by multiple roll forming equipment; and the workpiece on one side of the reference plane can form two or more levels of bent wall features by multiple roll forming equipment.

[0014] Preferably, in the above-mentioned roll forming process, in the primary roll forming step, the workpiece on the first side of the reference plane is uniformly bent by multiple roll forming equipment to reach a first preset angle, and the difference in bending angle between the multiple roll forming equipment and the workpiece on the first side of the reference plane is within a preset error, which is 1 degree to 3 degrees.

[0015] Preferably, in the above roll forming process, the finished product angle is the forming angle between the workpiece on the second side of the reference plane and the reference plane;

[0016] The finished product angle is less than the seventh preset angle and greater than the fifth preset angle.

[0017] Preferably, in the above-mentioned roll forming process, in the second and third workpiece rotation steps, the angle between the workpiece on the first side of the reference plane and the reference plane is maintained at a fourth preset angle.

[0018] Preferably, in the above roll forming process, during one workpiece rotation step, the end of the reference plane near the first side is raised and tilted.

[0019] Preferably, in the above-mentioned roll forming process, the first workpiece rotation step and the second roll forming step are performed in the same roll forming pass.

[0020] Preferably, the above roll forming process further includes the step of:

[0021] Uncoiling involves unwinding a coiled sheet of metal into a flat sheet using an uncoiler.

[0022] The first leveling step involves using a leveling machine to level the sheet material after the uncoiling process, eliminating internal stress and deformation, and making its surface smooth.

[0023] The material is stored between the uncoiler and the leveler, and between the leveler and the roll press, and is arranged in an arc shape to avoid the material being stretched.

[0024] Pre-punching: Punching holes in the sheet metal before roll forming; the pre-punched sheet metal then undergoes the primary roll forming step.

[0025] After the workpiece is produced through three rotation steps, it enters the straightening frame to straighten its straightness, and then is cut into the required production specifications by the cutting machine.

[0026] A roll forming apparatus for roll forming sheet metal using any of the roll forming processes described above; the roll forming apparatus includes at least a primary combination roller for rotating the workpiece once, the primary combination roller including a main roller, and the primary combination roller tilting the workpiece via the main roller.

[0027] As can be seen from the above technical solution, one aspect of this disclosure provides a roll forming process. In the process of producing roll-formed parts, a primary roll forming step is performed to locate a reference plane in the middle area of ​​the workpiece and pre-process the workpiece structure on both sides of the reference plane for preliminary roll forming bending. The workpiece on the first side of the reference plane is rolled to a state with a first preset angle to the reference plane, and the workpiece on the second side of the reference plane is rolled to a state with a second preset angle to the reference plane, while keeping the reference plane horizontal. After the primary roll forming, the workpiece is tilted so that the reference plane forms an acute angle with the horizontal direction at a third preset angle. For the tilted workpiece, the two sides of the reference plane are further rolled and folded to fold the single-sided folded edge structure into place. For the structure on the other side of the reference plane, the workpiece is further flipped and rolled simultaneously in a secondary workpiece rotation step to effectively roll the rounded corner position through the main roller in the tilted state. At the same time, the tilt angle of the workpiece is adjusted in a third workpiece rotation step to adjust the workpiece area after further roll forming and folding, thereby completing the overall roll forming requirements of the workpiece. The above steps adjust the overall tilt of the workpiece to enable bending of the rounded corner area in the vertical direction using vertical pressure rollers, reducing or even eliminating the use of cantilevered rollers and thus lowering the cost of rolling. At the same time, by combining the second and third workpiece rotation steps, the rounded corner area is rolled and retracted, thereby avoiding the risk of negative angles above the rounded corner, solving the problem of sidewall angle springback, and improving the structural stability of the rolled parts. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1This is a flowchart illustrating the roll forming process steps provided in an embodiment of the present disclosure;

[0030] Figure 2 This is a flow chart of a roll forming process provided in an embodiment of the present disclosure;

[0031] Figure 3 A schematic diagram of the rear compartment upper panel structure is provided for one embodiment of this disclosure;

[0032] Figure 4 for Figure 3 Mid-section view;

[0033] Figures 5-23 The following are schematic diagrams of the sequential production structure of a workpiece from the first to the nineteenth stage, according to an embodiment of this disclosure.

[0034] A schematic diagram showing the locking mechanism between the gear plate and the left half-shaft gear;

[0035] Figure 24 A schematic diagram of the fifteenth rolling structure provided in an embodiment of this disclosure;

[0036] Figure 25 This is a schematic diagram of the sixteenth rolling structure provided in an embodiment of the present disclosure.

[0037] in:

[0038] 10 - Reference plane; 20 - First side; 30 - Second side; 40 - Upper side plate of rear compartment; 50 - Main roller. Detailed Implementation

[0039] The core of this application is to disclose a roll forming process and roll forming equipment to reduce the production cost of roll-formed parts.

[0040] To enable those skilled in the art to better understand the present application, embodiments of the present application will be described below with reference to the accompanying drawings. Furthermore, the embodiments shown below do not limit the scope of the invention as described in the claims. Additionally, the complete contents of the structures represented in the following embodiments are not limited to those necessary for the solution of the invention described in the claims.

[0041] like Figure 1 and Figure 2 As shown, this disclosure provides a roll forming process for producing roll-formed parts. Specifically, the roll forming process includes at least the following steps:

[0042] S10: Primary rolling: A reference plane 10 is positioned in the middle area of ​​the workpiece. The workpiece structure on both sides of the reference plane 10 is gradually rolled through multiple rolling equipment. The acute angle between the workpiece on the first side 20 of the reference plane 10 and the reference plane 10 is a first preset angle, and the acute angle between the workpiece on the second side 30 of the reference plane 10 and the reference plane 10 is a second preset angle. The reference plane 10 remains horizontal during the primary rolling process.

[0043] It should be noted that in step S10, the initial rolling action on the workpiece is the same as the current rolling production process. That is, after determining the reference plane 10, the rolling process of multiple passes only performs rolling bending action on the workpiece areas on both sides of the reference plane 10, while the reference plane 10 remains horizontal under the action of the main roller. In step S10, the acute angle between the workpiece on the first side 20 of the reference plane 10 and the reference plane 10 is a first preset angle, and the acute angle between the workpiece on the second side 30 of the reference plane 10 and the reference plane 10 is a second preset angle. Both the first preset angle and the second preset angle are smaller than the target forming angle of the structure on both sides of the reference plane 10, and the rolling bending action continues to be performed in the subsequent processing.

[0044] It should also be noted that, in order to avoid the risk of local stress concentration and fracture in the areas on both sides of the reference plane 10 of the workpiece due to excessive bending in a single operation during the rolling process, in this embodiment, the acute angle between the workpiece on the first side 20 of the reference plane 10 and the reference plane 10 is a first preset angle, and the acute angle between the workpiece on the second side 30 of the reference plane 10 and the reference plane 10 is a second preset angle, the rolling process is completed by a multi-pass rolling equipment. Each pass of the rolling equipment performs a small angle bend, thereby realizing the gradual rolling processing of the workpiece. In some embodiments, in order to improve the uniformity of stress on the workpiece in the multi-pass rolling equipment, the bending angles performed on the first side 20 and the second side 30 of the reference plane 10 of the workpiece in step S10 are similar, and the bending angles applied by any two passes of the rolling equipment are within a preset error, and the preset error is 1 degree to 3 degrees to reduce the risk of fracture caused by uneven deformation of the workpiece.

[0045] Furthermore, the roll forming process provided in this disclosure, after step S10 is completed, also includes the following steps:

[0046] S20: Rotate the workpiece once to tilt it, so that the reference plane 10 forms an acute angle with the horizontal direction at a third preset angle.

[0047] S30: Secondary rolling, rolling the workpieces on both sides of the reference plane 10; the angle between the workpiece on the first side 20 of the reference plane 10 and the reference plane 10 is reduced from the first preset angle to the fourth preset angle during rolling, and the angle between the workpiece on the second side 30 of the reference plane 10 and the reference plane 10 is increased from the second preset angle to the fifth preset angle during rolling.

[0048] It should be noted that in the roll forming process provided in this embodiment, after step S10 is completed, the workpiece structure needs to be further bent. However, the commonly used main roller is difficult to perform the bending operation. Using a thinner main roller to continue bending will cause the reference plane 10 to be deformed, and the bending structure on one side will continue to fold towards the main roller. At the same time, a negative angle will appear at the top of the bending rounded corner, which will cause the workpiece to spring back after forming. Currently, inclined cantilevered rollers are often used to further process the bending rounded corner. In this disclosure, the workpiece is tilted in step S20. It should be noted that in this step, the docking plane of the main roller can be adjusted so that the roller below has an inclined plane, so that the workpiece can be tilted based on the horizontal plane when it reaches the roller equipment of the corresponding pass.

[0049] It should be further explained that, in step S20, the inclination of the reference plane 10 is specifically that the end of the reference plane 10 near the first side 20 is raised, while the end of the reference plane 10 near the second side 30 is relatively lowered to present an inclined structure, so that the connection rounded corner structure between the reference plane 10 and the second side 30 can be exposed in the vertical direction. Thus, without the aid of the cantilevered inclined roller, the main roller can contact the connection rounded corner area between the reference plane 10 and the second side 30 in the vertical direction and perform further rolling processing on the second side 30.

[0050] Based on this, in step S30, the workpiece areas on both sides of the reference plane 10 are further rolled. It should be noted that for the areas on both sides of the reference plane 10 with different folding angle requirements, in step S10, for the workpiece area on the first side 20 of the reference plane 10, it has already been bent to a state with the reference plane 10 at a first preset angle, and the first preset angle is greater than the finished bending angle required for the first side 20. Therefore, in step S30, when the tilted workpiece is further rolled, the first side 20 is bent back by the main roller and the auxiliary roller on one side, so that the angle between the structure of the first side 20 and the reference plane 10 is reduced from the first preset angle to the fourth preset angle, so as to achieve the bending angle requirement of the first side 20.

[0051] Furthermore, it should be noted that by first folding the structure of the first side 20 of the reference plane 10 to the first preset angle and then retracting it to the fourth preset angle, the risk of negative angles in the bending area of ​​the first side 20 can be avoided. Moreover, the internal stress in the bending rounded corner area can be relieved by the retraction action, thereby preventing the finished product from deforming in the retraction direction and affecting the finished product accuracy.

[0052] For the workpiece structure on the second side 30 of the reference plane 10, step S30 further processes its bent rounded corner area to increase the angle between the second side 30 and the reference plane 10 from the second preset angle to the fifth preset angle.

[0053] It should be noted that in this embodiment, the angle between the second side 30 of the reference plane 10 and the first side 20 relative to the reference plane 10 needs to be larger, thus requiring further processing. Therefore, after tilting the workpiece, while bending and retracting the area of ​​the first side 20, the second side 30 is further bent. Similarly, the single bending angle of the second side 30 by the single-pass roller equipment cannot be too large to avoid the risk of bending damage to the second side 30. Therefore, based on the above embodiment, the roll forming process provided by this disclosure embodiment further includes the following steps:

[0054] S40: The workpiece is rotated twice and tilted in the same direction. The acute angle between the reference plane 10 and the horizontal direction increases from the third preset angle to the sixth preset angle. The angle between the workpiece on the second side 30 of the reference plane 10 and the reference plane 10 increases from the fifth preset angle to the seventh preset angle.

[0055] Specifically, in step S40, in order to meet the bending requirements of the second side 30 of the reference plane 10, the workpiece needs to be tilted in the same direction to increase the tilt angle between the reference plane 10 and the horizontal plane. Then, the second side 30 of the reference plane 10 is further rolled by the main roller. The tilting progress of the reference plane 10 and the bending angle of the second side 30 are executed synchronously, so that the connecting rounded corners of the reference plane 10 and the second side 30 can remain in a similar state during the bending process of the second side 30, reducing the risk of excessive deformation and abnormal bending in the rounded corner area.

[0056] Furthermore, after step S40, the angle between the second side 30 of the reference plane 10 and the reference plane 10 is increased from a fifth preset angle to a seventh preset angle. The seventh preset angle is greater than the required finished angle of the second side 30, while the fifth preset angle is less than the finished angle. This results in the second side 30 region of the reference plane 10 being excessively folded in the workpiece after step S40. Based on this, the roll forming process provided in this embodiment of the present disclosure further includes the following steps:

[0057] S50: The workpiece is rotated three times, and the workpiece is tilted in the opposite direction. The acute angle between the reference plane 10 and the horizontal direction is reduced from the sixth preset angle to the eighth preset angle. The angle between the workpiece on the second side 30 of the reference plane 10 and the reference plane 10 is rolled from the seventh preset angle to the preset angle.

[0058] It should also be noted that in step S50, the tilt angle of the workpiece is adjusted so that the bending process of the reference plane 10 and the rounded corner area of ​​the second side 30 can be achieved in the vertical direction by using the vertical pressure roller. For the rounded corner area where the second side 30 connects to the reference plane 10, the risk of negative angles above the rounded corner is avoided by the process of excessive folding and reversal folding, which solves the problem of sidewall angle springback and improves the finished product stability of the roll forming part. In addition, in the above roll forming process, the tilting of the workpiece and the further roll forming of the second side 30 can be achieved by using the vertical main roller, reducing or even avoiding the use of cantilever inclined rollers, thereby reducing the roll forming cost.

[0059] Furthermore, in the roll forming process provided in the embodiments of this disclosure, for steps S20 and S30, the tilting of the workpiece and the further roll forming of the areas on both sides of the reference plane 10 can both be achieved by the main roller. In some embodiments, steps S20 and S30 can be performed in two passes of the roll forming equipment, that is, the tilting of the workpiece is performed at one station, and the further roll forming of the areas on both sides of the reference plane 10 is performed at the next station. Similarly, in other embodiments, steps S20 and S30 can also be performed in one pass of the roll forming equipment, so that the tilting and roll forming requirements of the workpiece can be performed simultaneously by the main roller, thereby reducing the total length setting of the roll forming equipment and improving the production economy of the roll forming parts.

[0060] Furthermore, in some embodiments, in order to reduce the risk of rolling, in step S40, the further tilting angle of the workpiece and the further rolling angle of the second side 30 are both performed with smaller angles to improve production safety. Correspondingly, between steps S20 and S50, step S40 can be repeatedly performed in multiple passes. Preferably, step S40 is performed at least twice in stages to perform multi-stage rolling on the structure of the second side 30 of the reference plane 10 to improve the production stability of the rolled parts.

[0061] Furthermore, it should be noted that for the regions on both sides of the reference plane 10, there are embodiments with different structural requirements. In step S10, before bending, the workpiece regions on both sides of the reference plane 10 are also rolled by a multi-roller pressing device to form height features, and then follow the workpiece to perform subsequent bending actions synchronously. This allows the workpiece on one side of the reference plane 10 to form two or more levels of bending wall features in the finished workpiece through a multi-roller pressing device, thereby meeting the more complex finished structure requirements of the workpiece, such as local protrusions and multi-level folds.

[0062] Furthermore, in the roll forming process provided in the embodiments of this disclosure, in step S30, since the area of ​​the first side 20 of the reference plane 10 has completed the folding requirement, it is preferable that in the subsequent steps S40 and S50, the angle between the workpiece on the first side 20 of the reference plane 10 and the reference plane 10 is maintained at a fourth preset angle, thereby reducing energy waste caused by repetitive operations.

[0063] In addition, such as Figure 2 As shown, the roll forming process provided in this embodiment further includes the following steps:

[0064] S01: Uncoiling, which unwinds a coiled metal sheet into a flat sheet using an uncoiler.

[0065] S02: First leveling, using a leveling machine to level the sheet material after the uncoiling step, eliminating internal stress and deformation of the sheet material, and making its surface flat.

[0066] S03: Material storage, storing the sheet material between the uncoiler and the leveler, and between the leveler and the roll press, and forming an arc structure to avoid tensioning the sheet material.

[0067] S04: Pre-punching: Punching holes in the sheet metal before roll forming. The sheet metal after pre-punching is subjected to the primary roll forming step.

[0068] It should be noted that steps S01, S02, S03 and S04 are all executed before step S10.

[0069] This roll forming process also includes:

[0070] S60: Correction and length cutting. After the workpiece is produced by three rotation steps, it enters the correction frame to correct its straightness, and then is cut by the cutting machine to the required production specifications.

[0071] Step S60 is executed after step S50, after the workpiece has been rolled, and the rolled part finished product that meets the specifications is output.

[0072] Furthermore, the following description will be given using a specific embodiment of this disclosure as an example, such as... Figure 3 As shown, the required structure is the upper side panel of the vehicle's rear cargo box, 40mm in size, produced using a roll forming process. Specifically, the product's external dimensions are 1610*36*72 (mm), the material is B280VK, the material thickness is 1.6mm, and the weight is 3.027KG. The product's cross-sectional dimensions are as follows. Figure 4 As shown, after steps S01-S04, the material begins to undergo rolling. This rolling forming process consists of 19 passes, as follows: Figures 5-23 As shown, the process details for each pass are as follows:

[0073] First pass: The sheet material is fed into the first pass rollers for rolling. After rolling, a feature with a height of 2.9mm is formed on the right end of the sheet material, and a 14-degree bent sidewall is formed on the left end of the sheet material.

[0074] Second pass: The sheet material that has passed the first pass of rolling smoothly enters the second pass of rolling. After rolling, the characteristic height of the right end of the sheet material becomes 4.2mm, and the side wall angle of the left end of the sheet material becomes 39 degrees.

[0075] Third pass: The sheet material that has passed the second pass of rolling smoothly enters the third pass of rolling. After rolling, the characteristic height of the right end of the sheet material becomes 5.4mm, and the side wall angle of the left end of the sheet material becomes 64 degrees.

[0076] Fourth pass: The sheet material that has passed the third pass of rolling smoothly enters the fourth pass of rolling. After rolling, the characteristic height of the right end of the sheet material becomes 6.4mm, and the side wall angle of the left end of the sheet material becomes 89 degrees.

[0077] Fifth pass: The sheet material that has passed the fourth pass of rolling smoothly enters the fifth pass of rolling. After rolling, the right end of the sheet material, that is, the second side 30 of the reference plane 10, forms a side wall with an angle of 5 degrees, and the left end, that is, the first side 20 of the reference plane 10, forms a second side wall with an angle of 7 degrees.

[0078] Sixth pass: The sheet material that has passed the fifth pass of rolling smoothly enters the sixth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 12 degrees; the second side wall angle of the left end becomes 16 degrees.

[0079] Seventh pass: The sheet material that has passed the sixth pass of rolling smoothly enters the seventh pass of rolling. After rolling, the right side wall angle of the sheet material becomes 19 degrees; the second side wall angle of the left end becomes 25 degrees.

[0080] Eighth pass: The sheet material that has passed the seventh pass of rolling smoothly enters the eighth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 26 degrees; the second side wall angle of the left end becomes 33 degrees.

[0081] Ninth pass: The sheet material that has passed the eighth pass of rolling smoothly enters the ninth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 33 degrees; the second side wall angle of the left end becomes 41 degrees.

[0082] Tenth pass: The sheet material that has passed the ninth pass of rolling smoothly enters the tenth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 40 degrees; the second side wall angle on the left end becomes 49 degrees.

[0083] Eleventh pass: The sheet material that has passed the tenth pass of rolling smoothly enters the eleventh pass of rolling. After rolling, the right side wall angle of the sheet material becomes 47 degrees; the second side wall angle of the left end becomes 57 degrees.

[0084] Twelfth pass: The sheet material that has passed the eleventh pass of rolling smoothly enters the twelfth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 54 degrees; the second side wall angle of the left end becomes 62 degrees.

[0085] Thirteenth pass: The sheet material that has passed the twelfth pass of rolling smoothly enters the thirteenth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 61 degrees; the second side wall angle of the left end becomes 70 degrees.

[0086] Fourteenth pass: The sheet material that has passed the thirteenth pass of rolling smoothly enters the fourteenth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 68 degrees; the second side wall angle of the left end becomes 78 degrees.

[0087] Fifteenth pass: The sheet material that has passed the fourteenth pass of rolling smoothly enters the fifteenth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 75 degrees; the second side wall angle of the left end becomes 86 degrees.

[0088] Sixteenth pass: The sheet material that has passed the fifteenth pass of rolling smoothly enters the sixteenth pass of rolling. After rolling, the right side wall angle becomes 82 degrees; the second side wall angle becomes 83 degrees; and the middle plane rotates 4 degrees to ensure that the rounded corner of the right side wall has no negative angle. The main roller can be used instead of the suspended inclined roller.

[0089] Seventeenth pass: The sheet material that has passed the sixteenth pass of rolling smoothly enters the seventeenth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 88 degrees; the second side wall on the left side remains at 83 degrees, and the rotation angle of the middle plane becomes 7 degrees. This ensures that there is no negative angle at the rounded corner of the right side wall, so the main roller can be used instead of the suspended inclined roller.

[0090] Eighteenth pass: The sheet material that has passed the seventeenth pass of rolling smoothly enters the eighteenth pass of rolling. After rolling, the right side wall angle of the sheet material becomes 93 degrees; the second side wall on the left side remains at 83 degrees, and the rotation angle of the middle plane becomes 9 degrees. This ensures that there is no negative angle at the rounded corner of the right side wall, so the main roller can be used instead of the suspended inclined roller.

[0091] Nineteenth pass: The sheet material that has passed the eighteenth pass of rolling smoothly enters the nineteenth pass of rolling for shaping. After rolling, the right side wall angle of the sheet material becomes 90 degrees; the second side wall on the left end remains at 83 degrees, and the rotation angle of the middle plane becomes 8 degrees, which is consistent with the product shape. This ensures that there is no negative angle at the rounded corner of the right side wall, and the main roller can be used instead of the suspended inclined roller.

[0092] The following steps include: Correction: The sheet material, after passing through the nineteenth rolling process, smoothly enters the correction frame to correct the straightness of the product.

[0093] Cut to length: The products that have passed through the calibration frame are then cut by the cutting machine to obtain qualified products.

[0094] Furthermore, such as Figure 24 and Figure 25 As shown in the embodiments of this disclosure, a roll forming equipment is also provided. This roll forming equipment is applicable to the roll forming process provided in any of the above embodiments for roll forming of sheet metal. It should be noted that since the roll forming process has the technical effects provided in any of the above embodiments, the roll forming equipment also has the technical effects provided in any of the above embodiments, which will not be repeated here.

[0095] Furthermore, in the roll forming equipment provided in this embodiment, the corresponding pass includes a primary combination roller for rotating the workpiece once. The primary combination roller includes a main roller 50, and the primary combination roller tilts the workpiece through the main roller 50, so that the roll forming equipment does not need to use a cantilever inclined roller, thereby reducing the difficulty of inspection, maintenance and use of the roll forming equipment and improving the economy of the roll forming equipment.

[0096] The terms "first," "second," "left side," and "right side," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units may not be defined in the listed steps or units, but may include steps or units not listed.

[0097] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A roll forming process, characterized in that, At least the following steps are included: In the primary rolling process, a reference plane is positioned in the middle area of ​​the workpiece. The workpiece structure on both sides of the reference plane is folded by gradually rolling through multiple rolling devices. The acute angle between the workpiece on the first side of the reference plane and the reference plane is a first preset angle, and the acute angle between the workpiece on the second side of the reference plane and the reference plane is a second preset angle. The reference plane remains horizontal during the primary rolling process. The workpiece is rotated once, tilting the workpiece so that the reference plane forms an acute angle with the horizontal direction at a third preset angle; The two-stage rolling process rolls the workpieces on both sides of the reference plane. The angle between the workpiece on the first side of the reference plane and the reference plane is reduced from the first preset angle to the fourth preset angle during the rolling process, while the angle between the workpiece on the second side of the reference plane and the reference plane is increased from the second preset angle to the fifth preset angle during the rolling process. The workpiece is rotated twice and tilted in the same direction. The acute angle between the reference plane and the horizontal direction is increased from the third preset angle to the sixth preset angle. The angle between the workpiece on the second side of the reference plane and the reference plane is increased from the fifth preset angle to the seventh preset angle. The workpiece is rotated three times and tilted in the opposite direction. The acute angle between the reference plane and the horizontal direction is reduced from the sixth preset angle to the eighth preset angle. The angle between the workpiece on the second side of the reference plane and the reference plane is rolled from the seventh preset angle to the finished product angle.

2. The roll forming process as described in claim 1, characterized in that, Between the first workpiece rotation step and the third workpiece rotation step, the second workpiece rotation step is performed at least twice in stages.

3. The roll forming process as described in claim 1, characterized in that, In the primary rolling step, the workpieces on both sides of the reference plane are also formed with height features by multiple rolling equipment; and the workpiece on one side of the reference plane can form two or more levels of bent wall features by multiple rolling equipment.

4. The roll forming process as described in claim 1, characterized in that, In the primary rolling step, the workpiece on the first side of the reference plane is uniformly bent by a multi-rolling equipment to reach the first preset angle, and the difference in bending angle between the multi-rolling equipment and the workpiece on the first side of the reference plane is within a preset error, which is 1 degree to 3 degrees.

5. The roll forming process as described in claim 1, characterized in that, The finished product angle is the forming angle between the workpiece on the second side of the reference plane and the reference plane. The finished product angle is less than the seventh preset angle and greater than the fifth preset angle.

6. The roll forming process as described in claim 1, characterized in that, In the second and third workpiece rotation steps, the angle between the workpiece on the first side of the reference plane and the reference plane is maintained at a fourth preset angle.

7. The roll forming process as described in claim 1, characterized in that, During the first workpiece rotation step, the end of the reference plane near the first side is raised and tilted.

8. The roll forming process as described in claim 1, characterized in that, The first workpiece rotation step and the second rolling step are performed in the same rolling pass.

9. The roll forming process as described in claim 1, characterized in that, It also includes the following steps: Uncoiling involves unwinding a coiled sheet of metal into a flat sheet using an uncoiler. The first leveling step involves using a leveling machine to level the sheet material after the uncoiling process, eliminating internal stress and deformation, and making its surface smooth. The material is stored between the uncoiler and the leveler, and between the leveler and the roll press, and is arranged in an arc shape to avoid the material being stretched. Pre-punching: Punching holes in the sheet metal before roll forming; the pre-punched sheet metal then undergoes the primary roll forming step. After the workpiece is produced through three rotation steps, it enters the straightening frame to straighten its straightness, and then is cut into the required production specifications by the cutting machine.

10. A roll forming equipment, characterized in that, The sheet metal is roll-formed using the roll forming process as described in any one of claims 1-9; the roll forming equipment includes at least a primary combination roller for performing the one-time rotation of the workpiece, the primary combination roller including a main roller, and the primary combination roller tilting the workpiece through the main roller.

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