Right-angle section steel forming system and method

Abstract

The invention discloses a right-angle section steel forming system and method. The system comprises a machining production line. A pre-pressing roller press; a heating unit; a forming roller press; wherein the pre-pressing roller press is used for rolling a profile steel material into pre-pressing channel steel with a raised bottom, and the forming roller press is used for rolling the pre-pressing channel steel into a channel steel finished product with a flat bottom and right-angled corners. The pre-pressing roller press is used for rolling the profile steel material into the pre-pressing groove profile steel with the raised bottom, and then the heating unit is used for conducting local heating treatment on the corner area so as to eliminate work hardening; a rolling channel with right-angled corners is formed in the forming rolling machine, pre-pressed channel steel passing through the rolling channel is rolled into right-angled U-shaped steel or channel steel with a flat bottom, and the problems of corner thinning, cracking and springback in cold roll forming of high-strength steel are effectively solved by rolling materials and guiding the materials to flow and fill directionally. And products with small external corner radiuses and approximately right-angled appearances can be obtained.

Description

Technical Field

[0001] This application relates to the field of hot roll forming technology, and in particular to a right-angle steel forming system and method. Background Technology

[0002] The current production of right-angle U-shaped steel mainly relies on integral hot rolling or assembly welding. The former has high energy consumption, serious pollution, and poor flexibility; the latter has many welds, large residual stress, and low precision.

[0003] While traditional roll forming is highly efficient, it suffers from work hardening at the corners when processing high-strength steel, making it prone to thinning and cracking. The large outer corner radius also results in severe springback, making it difficult to meet the requirements of high strength, precision, and mass production. Summary of the Invention

[0004] This application provides a right-angle steel forming system and method.

[0005] In a first aspect, this application proposes a right-angle steel forming system, including a processing line for conveying steel materials; Pre-compression roller presses are installed on the processing production line; The heating unit is arranged on the processing production line and is located behind the pre-press roller press along the conveying direction of the processing production line. The forming roller press is arranged on the processing production line and is located behind the heating unit along the conveying direction of the processing production line; Among them, the pre-pressing roller press is used to pre-press the steel material into a pre-pressed channel steel with a raised bottom, and the forming roller press is used to press the pre-pressed channel steel into a channel steel finished product with a flat bottom and right angles.

[0006] In some embodiments, the preload roller press includes a first preload roller, and the center of the first preload roller is provided with an annular recess in the radial direction; The second preload roller has an annular protrusion in the center along the radial direction, and the shape of the annular protrusion matches that of the annular concave portion. The annular protrusions and annular concave parts are corresponding and spaced apart.

[0007] In some embodiments, the annular protrusion includes a frustum portion and two conical portions; Along the axial direction of the annular protrusion, the two conical parts are located on both sides of the frustum, and the radial cross section of the conical part gradually decreases from the side closer to the frustum to the side farther away from the frustum.

[0008] In some embodiments, multiple pre-press roller presses are arranged sequentially at intervals along the conveying direction of the processing line, and the diameter of the annular protrusions on the multiple second pre-press rollers gradually increases.

[0009] In some embodiments, along the conveying direction of the processing line, the annular protrusions of the plurality of second preload rollers gradually decrease in size along the axial direction.

[0010] In some embodiments, the forming roll press includes a first forming roll and a second forming roll spaced apart along the direction of the bottom thickness of the pre-pressed groove steel, and a third forming roll and a fourth forming roll spaced apart along the direction of the bottom width of the pre-pressed groove steel. Projected along the conveying direction of the processing line, the first forming roller, the second forming roller, the third forming roller, and the fourth forming roller enclose a forming channel with right angles at the corners. The first forming roller has an extrusion section along its circumference. The extrusion section and the second forming roller together extrude the bottom of the pre-compressed groove steel in the forming channel, guiding the raised bottom material of the pre-compressed groove steel to fill the corner.

[0011] In some embodiments, multiple forming roller presses are arranged along the conveying direction of the processing line, and the distance between the extrusion section and the second forming roller gradually decreases.

[0012] In some embodiments, the first forming roller includes a first portion and a second portion, wherein the second portion is centrally disposed on the outer peripheral side of the first portion; Along the axial direction of the first forming roller, the size of the first part is larger than the size of the second part to form an extrusion section.

[0013] In some embodiments, a temperature measuring unit is also included, which is located between the heating unit and the forming roller press along the conveying direction of the processing line.

[0014] Secondly, this application proposes a method for forming right-angle steel, based on the right-angle steel forming system proposed in the first aspect; The steel profile is pre-rolled using a pre-roll press to obtain a pre-rolled steel profile with a raised bottom. The corner areas of the pre-compressed grooved steel are heated by a heating unit; The bottom of the heated pre-pressed channel steel is rolled by a forming roller press to make the pre-pressed channel steel into a finished channel steel product with a flat bottom and right angles.

[0015] Compared to existing technologies, the right-angle steel forming system proposed in this application pre-presses the steel material into a pre-pressed channel steel with a raised bottom using a pre-pressing roller press, forming a material reserve. Then, a heating unit is used to locally heat the corner area to eliminate work hardening. Inside the forming roller press, a roller pressing channel with right angles is formed. The pre-pressed channel steel passing through the roller pressing channel is rolled into a right-angled U-shaped steel or channel steel with a flat bottom. By extruding the material and guiding the material to flow in a directional manner, the system effectively solves the problems of corner thinning, cracking, and springback in the cold bending forming of high-strength steel. It can also produce products with a small outer corner radius and an appearance close to right angles, while avoiding the problems of weld seams and high energy consumption of hot rolling, significantly improving product precision and forming quality. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a right-angle steel forming system disclosed in an embodiment of this application; Figure 2 This is a simplified schematic diagram illustrating the engagement of the first and second preload rollers in the first pass of the preload roller press disclosed in the application embodiment. Figure 3 This is a simplified schematic diagram illustrating the cooperation between the first and second preload rollers of the second-pass preload roller press disclosed in the application embodiment. Figure 4 This is a simplified structural diagram of the pre-compression roller press disclosed in the application embodiment; Figure 5 This is a simplified schematic diagram of the heating unit disclosed in the application embodiment; Figure 6 This is a simplified schematic diagram showing the cooperation of the first forming roller, second forming roller, third forming roller, and fourth forming roller of the forming roller press disclosed in the application embodiment; Figure 7 This is a simplified structural diagram of a forming roller press for one of the first to third passes disclosed in the application embodiment; Figure 8 The embodiments disclosed in the application Figure 7 A simplified diagram of a magnified local structure; Figure 9 This is a simplified structural diagram of the fourth-pass forming roller press disclosed in the application embodiment. Figure 10 This is a simplified schematic diagram of the temperature measuring unit disclosed in the application embodiment.

[0017] Figure label: 10. Processing production line; 20. Pre-stressed channel steel; 100. Preload roller press; 101. First preload roller; 1011. Annular recess; 102. Second preload roller; 1021. Annular protrusion; 10211. Frustum; 10212. Conical portion; 1022. Support portion; 103. Preload base; 104. Preload frame; 105. Preload motor; 106. Preload reducer; 107. First preload coupling; 108. Second preload coupling; 109. First preload shaft; 110. Second preload shaft; 200. Heating unit; 201. Heating frame; 202. Heating element; 300. Forming roll press; 301. First forming roll; 3011. Extrusion section; 3012. First part; 3013. Second part; 302. Second forming roller; 303. Third forming roller; 304. Fourth forming roller; 305. Forming base; 306. Forming frame; 307. Forming motor; 308. Forming reducer; 309. First forming coupling; 310. Second forming coupling; 320. First forming shaft; 330. Second forming shaft; 340. Third forming shaft; 350. Fourth forming shaft; 360. Corner cavity; 400. Temperature measuring unit; 401. Temperature measuring frame; 402. Temperature measuring element; 500. Uncoiling machine; 600. Leveling machine; 700. Pre-bending roll press; 800. Cutting machine; 900. Bracket. Detailed Implementation

[0018] To better understand the technical solutions provided in the embodiments of this specification, the technical solutions of the embodiments of this specification will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments of this specification and the specific features in the embodiments are detailed descriptions of the technical solutions of the embodiments of this specification, rather than limitations on the technical solutions of this specification. In the absence of conflict, the embodiments of this specification and the technical features in the embodiments can be combined with each other.

[0019] In this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, without necessarily requiring or implying any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. The term "two or more" includes two or more cases.

[0020] The current production of right-angle U-shaped steel mainly relies on integral hot rolling or assembly welding. The former has high energy consumption, serious pollution, and poor flexibility; the latter has many welds, large residual stress, and low precision.

[0021] While traditional roll forming is highly efficient, it suffers from work hardening at the corners when processing high-strength steel, leading to thinning and cracking, large outer corner radii, and severe springback, making it difficult to meet the requirements of high strength, precision, and mass production. To address these issues, this disclosure pre-presses U-shaped steel or channel steel in the prior art to create a raised bottom, then heats and softens the corners. Upon entering the forming roll press, first and second forming rollers, spaced apart along the thickness direction of the U-shaped steel or channel steel's bottom, work together to flatten the raised bottom, causing the material to fill the right-angled contour area at the corners, thus obtaining a right-angled U-shaped steel or channel steel.

[0022] The raw materials used in this application are high-strength steel or ultra-high-strength steel with a yield strength range of 550MPa to 1200MPa. Such materials are prone to problems such as corner thinning, outer corner enlargement, cracking and excessive springback during traditional rolling processes. Therefore, based on these raw materials, this application proposes a right-angle steel forming system and method to produce the required right-angle U-shaped steel.

[0023] like Figure 1-10 As shown, in a first aspect, this application proposes a right-angle steel forming system, comprising: Processing line 10 is used for conveying structural steel materials; A pre-pressing roller press 100 is arranged on the processing production line 10; The heating unit 200 is arranged on the processing production line 10 and is located behind the pre-press roller press 100 along the conveying direction of the processing production line 10. The forming roller press 300 is arranged on the processing production line 10 and is located behind the heating unit 200 along the conveying direction of the processing production line 10. Among them, the pre-pressing roller press 100 is used to pre-press the steel material into a pre-pressed channel steel 20 with a raised bottom, and the forming roller press 300 is used to press the pre-pressed channel steel 20 into a channel steel finished product with a flat bottom and right angles.

[0024] Understandably, the processing line 10 includes an uncoiler 500, a straightener, a guide device, a drive roller, a cutting machine, etc., for continuous transport of strip steel; Before entering the pre-pressing roller press 100, the strip steel is pressed into U-shaped steel or channel steel. At this time, the corners of the product are rounded instead of right angles. The right-angle steel forming system disclosed herein can also directly use U-shaped steel or channel steel with non-right-angle corners produced by existing processes, and enter the processing production line 10 into the pre-pressing roller press 100 and subsequent processing passes.

[0025] For ease of description, U-shaped steel or channel steel is replaced with shaped steel. The pre-pressing roller press 100 rolls the bottom of the shaped steel to bulge, forming a smoothly transitioned arch shape, to obtain pre-pressed channel steel 20. The heating unit 200 is used to heat the corners of the steel profile, which then enters the forming roll press 300. The forming roll press 300 is formed by the forming rolls enclosing the forming channel, which is along the transport direction of the steel profile. The corners are right angles or rounded corners with a very small radius.

[0026] Under the combined effect of the forming roller applying extrusion pressure to the bottom of the pre-compression groove steel 20 and the softening of the corner material of the steel, the metal material is filled into the corner of the forming channel, so that the steel forms a right-angle profile in the forming channel.

[0027] The workflow is as follows: the strip steel is drawn from the uncoiler 500, straightened, and then enters the existing rolling mill. After initial bending, it forms U-shaped steel or channel steel (section steel). Then, it enters the pre-compression rolling mill 100 of this system and is rolled into a pre-compression channel steel 20 with a raised bottom. It then passes through the heating unit 200. Under the action of the heating unit 200, the corners on both sides are precisely heated and softened. Then, it enters the forming rolling mill 300. The raised bottom is flattened by the forming rollers, and the softened corner material is driven to fill the right-angle area inside the forming rolling mill 300, forming a channel steel product with a flat bottom and right-angled edges.

[0028] The heating unit 200 includes a heating frame 201 and a heating element 202. The heating frame 201 is fixedly disposed between the pre-pressing roller press 100 and the forming roller press 300. The heating element 202 is mounted on the heating frame 201, and the heating element 202 is positioned corresponding to the corner of the pre-compression groove steel 20. Local heating is applied to the corners of the pre-stressed channel steel 20, so that the bottom and sidewalls remain at room temperature and have structural strength, thus achieving the effect of local high plasticity and overall high strength of the pre-stressed channel steel 20.

[0029] The heating element 202 heats the corner of the pre-compressed channel steel 20 to soften the material in the corner area, reduce the yield strength of the material, and improve plasticity. Since the corner material is softened, it can flow easily in subsequent deformation, thus avoiding work hardening cracking. In addition, the plastic deformation capacity of the material in the hot state is enhanced and the elastic deformation ratio is reduced, so the springback is greatly reduced.

[0030] The heating element 202 can be heated by laser or contact resistance thermometer. In this embodiment, laser heating is used. A rectangular heating frame 201 is selected, and a single or multiple laser head is arranged at the bottom of the heating frame 201 to heat the corner of the pre-stressed slotted steel 20 to a temperature range of 750℃ to 1050℃, with temperature fluctuations not exceeding 20℃. The laser power range is 1kW to 20kW, and the spot diameter is 1mm to 15mm, so that the heating range is controlled within the corner area of ​​the pre-stressed slotted steel 20.

[0031] The right-angle steel forming system proposed in this application pre-rolls the steel material into a pre-rolled channel steel 20 with a raised bottom using a pre-roll press 100 to form a material reserve. Then, a heating unit 200 is used to locally heat the corner area to eliminate work hardening. The forming roll press 300 forms a roll pressing channel with right angles inside, and rolls the pre-rolled channel steel 20 through the roll pressing channel into a right-angled U-shaped steel or channel steel with a flat bottom. By extruding the material and guiding the material to flow in a directional manner, the system effectively solves the problems of corner thinning, cracking and springback in the cold bending forming of high-strength steel. It can also produce products with a small outer corner radius and an appearance close to right angles, while avoiding the problems of weld seams and high energy consumption of hot rolling, and significantly improving product precision and forming quality.

[0032] In some embodiments, the pre-pressing roller press 100 includes: a first pre-pressing roller 101, wherein an annular recess 1011 is radially provided in the middle portion of the first pre-pressing roller 101; and a second pre-pressing roller 102, wherein an annular protrusion 1021 is radially provided in the middle portion of the second pre-pressing roller 102, the annular protrusion 1021 and the annular recess 1011 having matching shapes; wherein the annular protrusion 1021 and the annular recess 1011 correspond to each other and are spaced apart.

[0033] Understandably, the first pre-pressing roller 101 can be the upper roller of the pre-pressing roller press 100, and the second pre-pressing roller 102 can be the lower roller of the pre-pressing roller press 100; in the middle of the first pre-pressing roller 101, an annular recess 1011 or an annular groove is formed along the circumferential direction. The cross-section can be arc-shaped, trapezoidal, or other smooth curved shapes.

[0034] In the middle of the second preload roller 102, an annular protrusion 1021 or an annular flange is provided corresponding to the annular recess 1011 or annular groove, and the shape and size match the annular recess 1011 of the first preload roller 101. Support portions 1022 are provided at both ends of the second preload roller 102 along the axial direction. The support portions 1022, the annular protrusion 1021 and the support portions 1022 together form a receiving groove.

[0035] During installation, the first pre-pressing roller 101 and the second pre-pressing roller 102 are installed correspondingly. The first pre-pressing roller 101 is partially placed in the receiving groove, and there is a gap between the two ends of the first pre-pressing roller 101 along the axial direction and the support part 1022. This gap is equal to the material thickness of the side wall of the U-shaped steel or channel steel (section steel) entering the pre-pressing roller press 100. The support part 1022 and the two ends of the first pre-pressing roller 101 along the axial direction together squeeze and limit the side wall of the section steel, so that it always remains perpendicular to the axis of the first pre-pressing roller 101. When the bottom of the section steel bulges, the side wall is prevented from expanding outward, thereby affecting the forming effect of the bottom bulge.

[0036] Furthermore, the annular recess 1011 and the annular protrusion 1021 are precisely aligned in the vertical direction, and a preset gap is maintained. This preset gap can be equal to or slightly smaller than the thickness of the bottom material of the U-shaped steel or channel steel (section steel) entering the pre-pressing roller press 100.

[0037] When the U-shaped steel or channel steel (section steel) that has been pre-bent and is in the shape of a shallow groove passes between the first pre-pressing roller 101 and the second pre-pressing roller 102 of the pre-pressing roller press 100, the annular protrusion 1021 of the second pre-pressing roller 102 rolls upward to press the bottom of the section steel, thereby obtaining the pre-pressed channel steel 20.

[0038] The annular recess 1011 of the first preload roller 101 and the annular protrusion 1021 of the second preload roller 102 cooperate to guide the metal at the bottom of the steel profile to undergo stretching and bending deformation, forming an upwardly bulging arch.

[0039] The contour of the annular recess 1011 determines the shape of the raised portion. For example, a wide and shallow recess can form a gentle raised portion. Through the cooperation of the annular recess 1011 and the annular protrusion 1021, the force of the pre-press roller press 100 is mainly applied to the bottom center area that needs to be deformed, while having less impact on the already formed side wall area.

[0040] In this embodiment, the pre-pressing roller press 100 also includes a pre-pressing base 103, a pre-pressing frame 104, a pre-pressing motor 105, a pre-pressing reducer 106, a first pre-pressing coupling 107, a second pre-pressing coupling 108, a first pre-pressing shaft 109, and a second pre-pressing shaft 110. The pre-pressure base 103 is fixedly installed on the processing production line 10. The pre-pressure frame 104 is located on the pre-pressure base 103. The first pre-pressure shaft 109 and the second pre-pressure shaft 110 are rotatably installed on the pre-pressure frame 104 through bearing seats in a parallel and spaced manner. The first pre-pressure roller 101 is fixedly connected to the first pre-pressure shaft 109, and the second pre-pressure roller 102 is fixedly connected to the second pre-pressure shaft 110, with the first pre-pressure roller 101 corresponding to it.

[0041] The preload motor 105 and the preload reducer 106 are used to provide a power source. The first preload coupling 107 and the second preload coupling 108 are used to transmit the driving force to the first preload shaft 109 and the second preload shaft 110 respectively, and drive the first preload roller 101 and the second preload roller 102 to rotate respectively.

[0042] In some embodiments, the annular protrusion 1021 includes a frustum portion 10211 and two conical portions 10212; along the axial direction of the annular protrusion 1021, the two conical portions 10212 are respectively located on both sides of the frustum portion 10211, and the radial cross section of the conical portion 10212 gradually decreases from the side closer to the frustum portion 10211 to the side farther away from the frustum portion 10211.

[0043] Understandably, the frustum portion 10211 is located in the central region of the annular protrusion 1021 and is used to lift most of the bottom area of ​​the steel section upward to form a raised top platform, and the width of the frustum portion 10211 is the same as the width of the raised portion.

[0044] Two conical portions 10212 are located on both sides of the frustum portion 10211. Starting from the side closer to the frustum portion 10211, the radius or height gradually decreases towards the side away from the frustum portion 10211, forming a smooth slope. The slope surface can be linear or slightly arc-shaped, used to ensure a smooth transition of the bottom material of the steel section.

[0045] The radial cross-sectional area of ​​the connection between the conical portion 10212 and the frustum portion 10211 is the same.

[0046] In some embodiments, a plurality of pre-press roller presses 100 are arranged sequentially at intervals along the conveying direction of the processing line 10, and the diameter of the annular protrusions 1021 on the plurality of second pre-press rollers 102 gradually increases.

[0047] Understandably, the pre-pressing roller press 100 includes at least two units, which are used to gradually raise the bottom of the steel section, decompose the total deformation required at the bottom of the steel section, and the deformation of each pass is small, so the springback is also small. Through multiple passes of the pre-pressing roller press 100, the stress is gradually corrected and released, and finally the shape of the pre-pressed channel steel is stable, which also makes the gradual forming process more stable and controllable.

[0048] In some embodiments, along the conveying direction of the processing line 10, the annular protrusions 1021 of the plurality of second preload rollers 102 gradually decrease in size along the axial direction.

[0049] Understandably, along the conveying direction of the processing line 10, the annular protrusions 1021 of the multiple second pre-pressing rollers 102 gradually change from wider annular protrusions 1021 to narrower annular protrusions 1021. The initial wider annular protrusions 1021 have a larger contact area with the bottom of the steel section, which can guide the bottom of the steel section to rise more smoothly and gently. The gradually narrowing annular protrusions 1021 can increase the pressure acting on the bottom of the steel section while the total pressure remains unchanged, effectively making the bottom rise higher.

[0050] In this process, multiple pre-pressing roller presses 100 are arranged sequentially along the conveying direction of the processing production line 10. The axial dimension of the annular protrusion 1021 of the second pre-pressing roller 102 gradually decreases and the diameter gradually increases, so that the bottom material of the steel section rises gently and stably.

[0051] In some embodiments, the forming roll press 300 includes a first forming roll 301 and a second forming roll 302 spaced apart along the thickness direction of the bottom of the pre-pressed groove steel 20, and a third forming roll 303 and a fourth forming roll 304 spaced apart along the width direction of the bottom of the pre-pressed groove steel 20. Projected along the conveying direction of the processing line 10, the first forming roller 301, the second forming roller 302, the third forming roller 303 and the fourth forming roller 304 enclose and form a forming channel with right angles at the corners. The first forming roller 301 is provided with an extrusion section 3011 along the circumference. The extrusion section 3011 and the second forming roller 302 together extrude the bottom of the pre-pressed groove steel 20 in the forming channel, guiding the raised bottom material of the pre-pressed groove steel 20 to fill the corner.

[0052] Understandably, the four rollers inside the forming roll press 300 together form a closed channel with a right-angled cross-section.

[0053] The first forming roller 301 and the second forming roller 302 are respectively arranged at intervals along the thickness direction of the bottom of the pre-pressed groove steel 20, located on the upper and lower sides of the workpiece. The first forming roller 301 is the upper roller and the second forming roller 302 is the lower roller, used to apply pressure to the workpiece in the vertical direction.

[0054] The third forming roller 303 and the fourth forming roller 304 are respectively arranged at intervals along the bottom width direction of the pre-pressed groove steel 20 and are located on the left and right sides of the workpiece. They are used to support and constrain the two side walls of the workpiece in the horizontal direction to prevent them from opening outward or becoming unstable during the forming process.

[0055] When projected along the conveying direction of the processing line 10, the working surfaces of the first forming roller 301, the second forming roller 302, the third forming roller 303 and the fourth forming roller 304 together enclose a channel with a precise right-angled U-shaped cross-section.

[0056] Since the corners of the channel are right angles, the top edges of the third forming roller 303 and the fourth forming roller 304, as well as the areas that connect with the first forming roller 301 and the second forming roller 302, are all at 90-degree angles.

[0057] The circumferential extrusion section 3011 of the first forming roller 301 is used to cooperate with the second forming roller 302 to extrude the raised portion at the bottom of the pre-compressed channel steel 20.

[0058] When the pre-compressed channel steel 20 with its bottom bulge enters the right-angle forming channel, the extrusion section 3011 of the first forming roller 301 and the second forming roller 302 work together to apply a strong, concentrated, and downward extrusion force to the bottom of the bulge, causing the material in the middle bulge to flow to both sides. Since the left and right sides and the bottom of the pre-compressed channel steel 20 are constrained by the third forming roller 303, the fourth forming roller 304, and the second forming roller 302, the material can only flow to the corner areas of the pre-compressed channel steel 20. Furthermore, since the corner areas have just been heated and softened, their plasticity is increased. Thus, under strong pressure, the material is squeezed and filled to the two right-angled corners of the forming channel.

[0059] In this embodiment, the forming roller press 300 also includes a forming base 305, a forming frame 306, a forming motor 307, a forming reducer 308, a first forming coupling 309, a second forming coupling 310, a first forming shaft 320, a second forming shaft 330, a third forming shaft 340, and a fourth forming shaft 350. A forming base 305 is fixedly mounted on the processing production line 10, and a forming frame 306 is fixedly mounted on the forming base 305. A first forming shaft 320 and a second forming shaft 330 are spaced apart and parallel to each other, and are rotatably mounted on the forming frame 306 via bearing seats. Both ends of the first forming shaft 320 and the second forming shaft 330 extend along the width direction of the bottom of the channel steel. One end of the first forming shaft 320 is rotatably connected to a first forming coupling 309, and one end of the second forming shaft 330 is rotatably connected to a second forming coupling 310. A first forming roller 301 is fixedly mounted on the outer periphery of the first forming shaft 320, and a second forming roller 302 is fixedly mounted on the outer periphery of the second forming shaft 330, corresponding to the first forming roller 301. The forming motor 307 and the forming reducer 308 are used to provide a power source. The first forming coupling 309 and the second forming coupling 310 are used to transmit the driving force to the first forming shaft 320 and the second forming shaft 330 respectively, and drive the first forming roller 301 and the second forming roller 302 to rotate respectively.

[0060] The third forming shaft 340 and the fourth forming shaft 350 are respectively mounted on the forming frame 306 via shaft seats, and the shaft seats are located between the first forming shaft and the second forming shaft 330. The two shaft seats are spaced apart and arranged relative to each other along the width direction of the bottom of the channel steel.

[0061] Both ends of the third forming shaft 340 and the fourth forming shaft 350 extend along the thickness direction of the bottom of the channel steel (i.e., perpendicular to the width direction). The third forming roller 303 is fixedly disposed on the outer periphery of the third forming shaft 340, and the fourth forming roller 304 is fixedly disposed on the fourth forming shaft 350. The first forming roller 301 extends partially between the first forming roller and the fourth forming roller 304. The peripheral surfaces of the third forming roller 303 and the fourth forming roller 304 cooperate with the first forming roller 301 to jointly form a limiting extrusion on the sidewall of the channel steel.

[0062] In some embodiments, a plurality of forming roller presses 300 are arranged along the conveying direction of the processing line 10, and the distance between the extrusion section 3011 and the second forming roller 302 gradually decreases.

[0063] Understandably, the forming roller press 300 comprises multiple units arranged sequentially along the production line conveying direction, and the gap between the extrusion section 3011 of the first forming roller 301 and the second forming roller 302 is set to gradually decrease. For example, the forming roller press 300, comprising at least three passes, is arranged sequentially along the production line conveying direction. In the first pass of the forming roller press 300, the gap between the extrusion section 3011 of the first forming roller 301 and the second forming roller 302 is the largest. The extrusion section 3011 contacts the top of the raised portion and begins to apply pressure. Due to the large gap, this pass only flattens a portion of the raised portion, and some material, guided by pressure, begins to flow towards the corner area for initial filling.

[0064] In the second pass of the forming roller press 300, the gap between the extrusion section 3011 of the first forming roller 301 and the second forming roller 302 is smaller than that of the first roller. Continuing the partially flattened shape from the previous pass, it performs deeper compression. More material is extruded from the bottom center area and flows towards the corners. At this point, the corner filling amount increases significantly, and the right-angled contours begin to clearly appear. Because the corner material has been heated and softened, and the deformation is gradual, it can smoothly fill the mold space. The spacing of the forming rollers 300 in the third pass is smaller than that in the second pass, and so on, until the forming rollers 300 in the last pass, ensuring that the bottom plate of the pre-pressed groove steel 20 is completely flattened to the target thickness, and forcing the last part of the material to completely fill every corner of the right-angle forming channel, forming a clear 90-degree angle.

[0065] Progressive filling allows sufficient material flow time, ensuring that corners are completely filled. By gradually reducing the roll gap, the final thickness of the base plate can be precisely controlled, avoiding excessive thinning or uneven thickness caused by excessive single pressing. It also greatly reduces springback, thereby improving dimensional accuracy.

[0066] In some embodiments, the first forming roller 301 includes a first portion 3012 and a second portion 3013, wherein the second portion 3013 is centrally disposed on the outer periphery of the first portion 3012. Along the axial direction of the first forming roller 301, the size of the first portion 3012 is larger than the size of the second portion 3013 to form the extrusion portion 3011.

[0067] Understandably, the first part 3012 and the second part 3013 together form the extrusion part 3011. Specifically, the second part 3013 is centrally located on the outer periphery of the first part 3012. The outer periphery of the second part 3013 and both sides of the second part 3013 form a stepped shoulder with the first part 3012, and the raised bottom and the end of the side wall are extruded by extending to the pre-compression groove steel 20.

[0068] The first part 3012 serves as the main structural component of the first forming roller 301. It is shaped as a cylinder with a large diameter to provide strength and rigidity. The outer circumferential surface of the first part 3012 can compress the end of the side wall of the channel steel.

[0069] The second part 3013 is annular and is located along the axial direction of the first forming roller 301, i.e., the width direction of the first forming roller 301. The width of the first part 3012 is greater than the width of the second part 3013. The annular second part 3013 is centrally and coaxially fitted onto the cylindrical first part 3012. The second part 3013 is a narrower annular shape than the first part 3012. As the functional entity of the extrusion part 3011, the outer peripheral surface of the second part 3013 is the working surface, which is used to directly contact and extrude the raised bottom surface of the pre-pressed channel steel 20.

[0070] Since the second part 3013 is centrally and coaxially fitted onto the first part 3012, the extrusion pressure of the first forming roller 301 on the pre-pressed groove steel 20 is evenly distributed, thereby ensuring that the bottom material extruded by the second part 3013 flows evenly to the corners on both sides to form symmetrical right angles. The first part 3012 and the second part 3013 can be integrally formed.

[0071] In some embodiments, a temperature measuring unit 400 is also included, which is located between the heating unit 200 and the forming roller press 300 along the conveying direction of the processing line 10.

[0072] Understandably, the temperature measuring unit 400 is located after the heating unit 200 and before the forming roller press 300. It is used to monitor the temperature of the two heated corners of the pre-pressed groove steel 20 and transmit the real-time temperature signal (which can be an electrical signal) to the central control system, such as a PLC. The real-time temperature is compared with the preset temperature. Based on the measured temperature, the central control system automatically adjusts the output power of the heating unit 200. If the temperature is lower than the preset temperature, the heating power of the heating unit 200 is increased.

[0073] The temperature measuring unit 400 includes a temperature measuring frame 401 and a temperature measuring element 402. The temperature measuring element 402 can be a non-contact infrared thermometer or a thermal imager. It is fixed between the heating unit 200 and the forming roller press 300 through the temperature measuring frame 401. The detection end of the temperature measuring unit 400 is facing the corner area of ​​the pre-pressed groove steel 20. The temperature measurement signal is transmitted to the central control system in real time, compared with the preset temperature, and the power output of the heating unit 200 is automatically adjusted.

[0074] The right-angle steel forming system disclosed in this application also includes an uncoiler 500, a leveler 600, a pre-bending roll press 700, a cutting pass 800, and a support 900. Along the conveying direction of the processing production line 10, the uncoiler 500, the leveler 600, and the pre-bending roll press 700 are sequentially arranged in front of the pre-press roll press 100, and the cutter 800 and the bracket 900 are sequentially arranged behind the forming roll press 300.

[0075] Understandably, the system operation process of this disclosure is as follows: A high-strength or ultra-high-strength steel strip with a yield strength range of 550MPa-1200MPa is uncoiled using an uncoiler 500 and fed into a leveler 600 for leveling; the steel strip is then rolled at specific angles and passed sequentially through multiple pre-bending roll presses 700 to roll the flat steel strip into U-shaped steel or channel steel, and then passed through a pre-pressing roll press 100 to obtain a pre-pressed channel steel 20 with a raised bottom; the two bending angles at the bottom of the pre-pressed channel steel 20 are heated by a heating unit 200 (laser heating device), and the temperature is measured by a temperature measuring unit 400 (infrared thermal imager device) to ensure a constant temperature; finally, it enters a forming roll press 300 to roll and form a right-angled steel section, which is then cut by a cutting machine 800 and subsequently conveyed to a support 900. The support 900 includes a frame and rollers, with multiple rollers arranged at intervals on the frame for supporting the product.

[0076] The pre-bending roll press 700 can include three passes. The pre-bending roll press includes an upper roll and a lower roll. The upper roll and the lower roll are matched in shape and size to gradually roll flat steel strip into U-shaped steel or channel steel. The pre-bending roll press 700 is a traditional existing roll pressing device, which will not be described in detail here. The pre-pressing roller press 100 may include two passes, which roll flat U-shaped steel or channel steel into pre-pressed channel steel 20 with raised bottom. The forming roll press 300 may include four passes. The first pass of the forming roll press 300 is used to compress the bottom of the pre-compressed groove steel 20 to induce initial plastic flow and fill the corner cavity 360 between the corner of the pre-compressed groove steel 20 and the forming channel (mold cavity) enclosed by the second forming roll 302, the third forming roll 303 and the fourth forming roll 304. The second forming roller press 300 performs dimensional control and finishing, the third forming roller press 300 performs overall shaping, and the fourth forming roller press 300 eliminates bending and twisting through tension. The final product is a right-angled U-shaped steel with a flat bottom and right angles at the edges.

[0077] The system disclosed herein can achieve an outer corner radius (the radius R of the arc outside the two corners of the U-shaped steel or channel steel) of less than 0.5 mm, an inner corner radius of 2.5 t, where t is the plate thickness, and a corner thickness that is 5% to 20% greater than that of the pre-stressed channel steel in stage 20. The residual stress is significantly reduced, and the springback is less than 30% of that of the pre-formed U-shaped steel.

[0078] In some embodiments, HC550 / 980DP high-strength steel is used as the raw material, with a plate thickness of 1.5mm and a yield strength of 700MPa. The pre-pressed channel steel 20 is heated by a laser heating unit 200, the roller press feed speed is 10m / min, the laser heating temperature is set to 850℃, and after being formed by a forming roller press 300 for 4 passes, a right-angled U-shaped steel with an outer corner radius of 0.3mm is obtained. The corner thickness is increased by about 10% compared with the initial thickness, the residual stress is reduced, and the dimensional accuracy is high.

[0079] In some embodiments, HC600 / 980QP ultra-high strength steel is used as the raw material, with a plate thickness of 2.0 mm and a yield strength of 850 MPa. The laser power is set to 12 kW, the roller press feed speed is 8 mm / min, and the laser heating temperature is set to 950℃. After being formed by a forming roller press 300 for 4 passes, a right-angled U-shaped steel with an outer corner radius of 0.4 mm is obtained, and the springback after forming is reduced by 40% compared with the traditional process.

[0080] In some embodiments, HC950 / 1180MS martensitic steel is used as the raw material, with a plate thickness of 3.0 mm and a yield strength of 1200 MPa. Laser heating is used, with the laser heating temperature set at 1050°C. The roller press feed speed is 5 m / min. After being formed by the forming roller press 300 for 4 passes, a right-angle U-shaped steel with an outer corner radius of 0.4 mm is obtained, and the corner thickness is increased by 15%, which meets the requirements of high-strength steel for mechanical equipment.

[0081] Secondly, this application proposes a method for forming right-angle steel, based on the right-angle steel forming system proposed in the first aspect; The steel profile material is pre-rolled using a pre-roll press 100 to obtain a pre-rolled grooved steel profile 20 with a raised bottom. The corner area of ​​the pre-compressed grooved steel 20 is heated by the heating unit 200; The pre-pressed channel steel 20 is pressed at the bottom by a forming roller press 300 to make it into a finished channel steel product with a flat bottom and right angles.

[0082] Understandably, the pre-pressing roller press 100 is used to pre-press the steel profile material. At this time, the steel profile material is a U-shaped steel or channel steel with non-right angle corners formed by the cold bending of the pre-bending roller press 700. It is then rolled into a pre-pressed channel steel 20 with a raised bottom. The heating unit 200 precisely and quickly heats the corner area of ​​the pre-compressed grooved steel 20, softening the corner material and improving its plasticity. This allows it to easily flow and fill right angles during rolling in the forming roll press 300, and significantly reduces springback after forming.

[0083] In the forming roll press 300, the extrusion section 3011 of the first forming roll 301 cooperates with the second forming roll 302 to flatten the raised bottom, so that the raised bottom flows in a direction towards the softened corner area and fills the right-angle mold cavity formed by the first forming roll 301, the second forming roll 302, the third forming roll 303, and the fourth forming roll 304, and finally obtains a channel steel product with a flat bottom and right-angled edges.

[0084] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

[0085] Although preferred embodiments have been described in this specification, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this specification.

[0086] Obviously, those skilled in the art can make various modifications and variations to this specification without departing from its spirit and scope. Therefore, if such modifications and variations fall within the scope of the claims and their equivalents, this specification is also intended to include such modifications and variations.

Claims

1. A right-angle steel forming system, characterized in that, include: Processing production line used for conveying structural steel materials; A pre-compression roller press is arranged on the processing production line; The heating unit is arranged on the processing production line and is located behind the pre-press roller press along the conveying direction of the processing production line. A forming roller press is arranged on the processing production line and is located behind the heating unit along the conveying direction of the processing production line; The pre-pressing roller press is used to press the steel material into a pre-pressed channel steel with a raised bottom, and the forming roller press is used to press the pre-pressed channel steel into a finished channel steel with a flat bottom and right angles.

2. The right-angle steel forming system according to claim 1, characterized in that, The pre-compression roller press includes: The first preload roller has an annular recess in the radial direction at the center. The second preload roller has an annular protrusion in the center along the radial direction, and the shape of the annular protrusion matches that of the annular recess. The annular protrusions and annular recesses are corresponding to each other and spaced apart.

3. The right-angle steel forming system according to claim 2, characterized in that, The annular protrusion includes a frustum portion and two conical portions; Along the axial direction of the annular protrusion, the two conical portions are located on both sides of the frustum portion, and the radial cross-section of the conical portion gradually decreases from the side closer to the frustum portion to the side farther away from the frustum portion.

4. The right-angle steel forming system according to claim 2 or 3, characterized in that, include: Multiple pre-press roller presses are arranged sequentially at intervals along the conveying direction of the processing production line, and the diameter of the annular protrusions on the multiple second pre-press rollers gradually increases.

5. The right-angle steel forming system according to claim 4, characterized in that, Along the conveying direction of the processing line, the annular protrusions of the plurality of second preload rollers gradually decrease in size along the axial direction.

6. The right-angle steel forming system according to claim 1, characterized in that, The forming roll press includes a first forming roll and a second forming roll spaced apart along the thickness direction of the bottom of the pre-pressed groove steel, and a third forming roll and a fourth forming roll spaced apart along the width direction of the bottom of the pre-pressed groove steel. Projected along the conveying direction of the processing line, the first forming roller, the second forming roller, the third forming roller, and the fourth forming roller enclose a forming channel with right angles at the corners; The first forming roller has an extrusion section along its circumference. The extrusion section and the second forming roller together extrude the bottom of the pre-compressed groove steel in the forming channel, guiding the raised bottom material of the pre-compressed groove steel to fill the corner.

7. The right-angle steel forming system according to claim 6, characterized in that, The system includes multiple forming roller presses arranged along the conveying direction of the processing line, and the distance between the extrusion section and the second forming roller gradually decreases.

8. The right-angle steel forming system according to claim 6 or 7, characterized in that, The first forming roller includes a first part and a second part, wherein the second part is centrally disposed on the outer periphery of the first part; Along the axial direction of the first forming roller, the size of the first portion is larger than the size of the second portion to form the extrusion section.

9. The right-angle steel forming system according to claim 1, characterized in that, Also includes: A temperature measuring unit is located between the heating unit and the forming roller press along the conveying direction of the processing production line.

10. A method for forming right-angled steel sections, characterized in that, Based on the right-angle steel forming system as described in any one of claims 1-9; The steel profile is pre-rolled using a pre-roll press to obtain a pre-rolled steel profile with a raised bottom. The corner area of ​​the pre-compressed grooved steel is heated by a heating unit; The pre-pressed channel steel is pressed at the bottom by a forming roller press to make it into a finished channel steel product with a flat bottom and right angles.

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