Right-angle curled profile steel forming system and method

Abstract

The invention discloses a right-angle curled profile steel forming system and method.The forming system comprises at least one rolling forming pass; the rolling forming pass comprises a first driving roller, a second driving roller and two driven rollers; the first driving roller and the second driving roller are arranged between the two driven rollers so as to define a rolling space; the core mold is fixedly arranged in the rolling space, and the core mold, the first driving roller, the second driving roller and the two driven rollers are arranged at intervals so as to form a rolling channel for the hemming profile steel to pass through; the core mold rigidly supports the inner wall of the hemming profile steel and cooperates with the first driving roller, the second driving roller and the driven roller to form a high-constraint forming environment, and pipe wall collapse and section distortion are effectively restrained. A material flowing mechanism is actively guided, it is ensured that the right-angle area is fully filled with materials, the angle contour definition and the size precision are remarkably improved, and the method is particularly suitable for high-precision machining of high-strength steel and other materials difficult to form.

Description

Technical Field

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

[0002] Inwardly rolled steel sections are key structural components in construction, automotive, and other fields, and the accuracy of their right-angle forming is crucial. Existing cold rolling processes for high-strength steel suffer from significant material springback and poor plasticity, making it difficult to form the corners and easily leading to pipe wall collapse and cross-sectional distortion, severely restricting product quality.

[0003] However, these methods are all passive compensations and cannot actively constrain material flow during the forming process. They have limited effectiveness for high-strength materials and right-angle forming, and the accuracy and stability of the finished product are still not ideal. Summary of the Invention

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

[0005] In a first aspect, this application proposes a right-angle rolled steel forming system, comprising: at least one roll forming pass; The roll forming process includes a first drive roller, a second drive roller, and two driven rollers; The first drive roller and the second drive roller are spaced apart and arranged in parallel, and the two driven rollers are spaced apart and arranged in parallel. The first drive roller and the second drive roller are arranged between the two driven rollers to enclose and form a roller pressing space. The core mold is fixedly set in the rolling space. The core mold, the first drive roller, the second drive roller and the two driven rollers are all spaced apart to form a rolling channel for the rolled steel to pass through. The core mold is used to form a rigid support for the inner wall of the rolled steel section, and works in conjunction with the first drive roller, the second drive roller and the two driven rollers to apply pressure, so as to guide the material of the rolled steel section to fill the target contour area of ​​the roller pressing channel, thereby forming a preset cross-sectional contour of the rolled steel section.

[0006] In some embodiments, the first drive roller, the second drive roller, and the two driven rollers together form a roll pressing space with a rectangular cross-section; The outer peripheral side of the core mold is arranged parallel to the axes of the corresponding first drive roller, second drive roller and two driven rollers, thereby forming a roll pressing channel with a rectangular frame cross-section; The right-angled contour area of ​​the roller pressing channel constitutes the target contour area.

[0007] In some embodiments, a connecting portion is provided on the outer periphery of the core mold, which is used to be fixedly connected to the support of the driven roller; the connecting portion is provided correspondingly to the open side of the rolled steel section.

[0008] In some embodiments, at least one roll forming pass includes a first forming pass, a second forming pass, and a third forming pass; Along the traveling direction of the rolled steel section, the first forming pass, the second forming pass, and the third forming pass are arranged in sequence, and the rolling space inside the first forming pass, the second forming pass, and the third forming pass gradually decreases.

[0009] In some embodiments, the distance between the first drive roller and the second drive roller of the first forming pass is a first height distance, and the distance between the two driven rollers of the first forming pass is a first width distance. The distance between the first and second drive rollers in the second forming pass is the second height distance, and the distance between the two driven rollers in the second forming pass is the second width distance. The distance between the first and second drive rollers in the third forming pass is the third height distance, and the distance between the two driven rollers in the third forming pass is the third width distance. The first height spacing is greater than the second height spacing, and the second height spacing is greater than the third height spacing; The first width spacing is greater than the second width spacing, and the second width spacing is greater than the third width spacing.

[0010] In some embodiments, a drive guide pass is also included, which is located in front of the roll forming pass along the direction of the rolled steel section.

[0011] In some embodiments, a heating unit is also included, which is disposed between the drive guide pass and the roll forming pass, for heating the corner area of ​​the rolled steel section.

[0012] In some embodiments, a temperature measuring unit is also included, which is located between the heating unit and the roll forming pass.

[0013] In some embodiments, the system further includes a cutting unit located after the roll forming pass, along the traveling direction of the rolled steel section.

[0014] In a second aspect, this application provides a method for forming right-angle rolled-edge steel, applicable to the right-angle rolled-edge steel forming system proposed in the first aspect, comprising: Obtain pre-formed rolled steel sections; Heating the corners of the rolled steel section; The heated rolled steel is passed through multiple roll forming passes in sequence. A core mold is provided in the roll forming space inside each roll forming pass, and the core mold supports the inner wall of the rolled steel. Along the direction of travel of the rolled steel section, the rolling space in multiple roll forming passes gradually decreases.

[0015] Compared to existing technologies, the right-angle rolled steel forming system proposed in this application uses a mandrel to rigidly support the inner wall of the rolled steel, which, together with the first drive roller, the second drive roller, and the driven roller, forms a highly constrained forming environment, effectively suppressing tube wall collapse and cross-sectional distortion. Its active material flow guidance mechanism ensures that the material fully fills the right-angle area, significantly improving the clarity of the corner contour and dimensional accuracy, making it particularly suitable for high-precision processing of difficult-to-form materials such as high-strength steel. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the right-angle rolled steel forming system proposed in this application; Figure 2 This is a schematic diagram of the roll forming space formed by the first drive roller, the second drive roller, and the driven roller in the roll forming process proposed in this application; Figure 3 This is a schematic diagram of the rolling channel formed by setting a core mold within the rolling space as proposed in this application; Figure 4 This is a schematic diagram of the roll forming process of the rolled steel profile proposed in this application; Figure 5 This is a schematic diagram of the roll forming process proposed in this application; Figure 6 This is a schematic diagram of the driven mechanism proposed in this application; Figure 7 This is a schematic diagram of the heating unit proposed in this application; Figure 8 This is a schematic diagram of the temperature measuring unit proposed in this application. Figure 9 This is a schematic diagram of the rolled steel structure before it enters the roll forming stage; Figure 10 This is a schematic diagram of the rolled steel structure after it enters the roll forming stage.

[0017] Figure label: 1. Flanged steel section; 1.1 Open side; 10. Roll forming pass; 11. First drive roller; 12. Second drive roller; 13. Driven roller; 14. Roll forming space; 15. Roll forming channel; 16. Motor; 17. Reducer; 18. First coupling; 19. Second coupling; 20. First drive mechanism; 201. First frame; 202. First drive shaft; 21. Second drive mechanism; 211. Second frame; 212. Second drive shaft; 22. Driven mechanism; 221. Driven frame; 222. Driven shaft; 223. Shaft bracket; 224. Adjustment assembly; 2241. Internal threaded sleeve; 2242. Threaded rod; 225. Support beam; 23. Main frame; 24. Base; 25. Core mold; 26. Connecting part; 30. First forming pass; 40. Second forming pass; 50. Third forming pass; 60. Drive guide pass; 70. Heating unit; 71. Heating frame; 72. Heating element; 80. Temperature measuring unit; 81. Detection end; 82. Mounting bracket; 90. Cutting unit; 100. Conveying unit. 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] like Figure 9As shown, the rolled steel section before entering the roll forming stage is a non-closed workpiece with an opening on one sidewall and non-right-angle corners. The material can be high-strength steel, ultra-high-strength steel, or stainless steel, with a yield strength range of 600MPa-1400MPa and a thickness range of 1mm-10mm. This type of steel, when formed using traditional cold roll forming, suffers from problems such as thinning, cracking, high residual stress, and springback at the corners due to the material's high yield strength ratio and low plasticity. This makes it difficult to guarantee the dimensional accuracy and right-angle precision. Hot rolling processes result in high energy consumption, while traditional assembly and welding processes suffer from numerous problems such as many welds, high residual force, and poor surface quality.

[0021] Therefore, in order to further improve the cold roll forming of high-strength steel materials and solve the technical problems such as insufficient corner filling, tube wall collapse and cross-section distortion caused by large springback and poor plasticity during the cold roll forming process, this disclosure proposes an active constraint forming system and method based on a built-in core mold.

[0022] like Figure 1-4 As shown, in a first aspect, this application proposes a right-angle rolled steel forming system, comprising: at least one roll forming pass 10; The roll forming pass 10 includes a first drive roller 11, a second drive roller 12, and two driven rollers 13; The first drive roller 11 and the second drive roller 12 are spaced apart and arranged in parallel, and the two driven rollers 13 are spaced apart and arranged in parallel. The first drive roller 11 and the second drive roller 12 are arranged between the two driven rollers 13 to enclose and form a roller pressing space 14. The core mold 25 is fixedly set in the rolling space 14. The core mold 25 is spaced apart from the first drive roller 11, the second drive roller 12 and the two driven rollers 13 to form a rolling channel 15 for the rolled steel 1 to pass through. The core mold 25 is used to form a rigid support for the inner wall of the rolled steel 1, and works in conjunction with the first drive roller 11, the second drive roller 12 and the two driven rollers 13 to apply pressure, so as to guide the material of the rolled steel 1 to fill the target contour area of ​​the roller pressing channel 15, thereby forming a preset cross-sectional contour of the rolled steel 1.

[0023] Understandably, the right-angle rolled steel forming system includes at least one roll forming pass 10, each roll forming pass 10 constituting an independent forming unit. The roll forming pass 10 includes a first drive roller 11, a second drive roller 12, and two driven rollers 13. The two driven rollers 13 are also spaced apart and arranged in parallel. The first drive roller 11 and the second drive roller 12 are spaced apart and arranged in parallel, constituting the active drive part, and are located between the two driven rollers 13. The four together enclose a rectangular roll forming space 14.

[0024] The core mold 25 is fixedly disposed inside the rolling space 14. The core mold 25 is spaced apart from the first drive roller 11, the second drive roller 12 and the two driven rollers 13, thereby forming a rolling channel 15 with a cross-sectional shape consistent with the target product between the outer peripheral surface of the core mold 25 and each roller, for the strip of the rolled steel 1 to pass through.

[0025] The mandrel 25 provides rigid support to the inner wall of the rolling steel section 1 during its movement, fundamentally preventing inward collapse or twisting deformation of the steel tube wall under roller pressure. Simultaneously, the outer circumferential surface of the mandrel 25, in conjunction with the first drive roller 11, the second drive roller 12, and the driven roller 13, applies pressure, effectively promoting the plastic flow of the material. The outer contour of the mandrel 25, especially the right-angle regions, precisely guides the material to fully fill each corner (i.e., the target contour region) of the roller pressing channel 15. Through this active constraint and guidance, the right-angle rolling steel section forming system can overcome the significant springback effect of high-strength steel, forcing the material to fill right-angle regions that are difficult to reach with traditional passive roller pressing, such as... Figure 10 As shown, the rolled steel section is ultimately formed into a preset high-precision cross-sectional profile, especially to obtain right angles with clear edges and full filling.

[0026] This application proposes a right-angle rolled steel profile forming system. Through the rigid support of the inner wall of the rolled steel profile 1 by the mandrel 25, it works in conjunction with the first drive roller 11, the second drive roller 12, and the driven roller 13 to form a highly constrained forming environment, effectively suppressing tube wall collapse and cross-sectional distortion. Its active material flow guidance mechanism ensures that the material fully fills the right-angle area, significantly improving the clarity of the corner contour and dimensional accuracy, making it particularly suitable for high-precision processing of difficult-to-form materials such as high-strength steel.

[0027] like Figure 2 As shown, in some embodiments, the first drive roller 11, the second drive roller 12, and the two driven rollers 13 together form a rolling space 14 with a rectangular cross-section; like Figure 3 As shown, the radial cross-section of the core mold 25 is rectangular, and the outer peripheral side of the core mold 25 is arranged parallel to the axes of the corresponding first drive roller 11, second drive roller 12 and two driven rollers 13, thereby forming a roll pressing channel 15 with a rectangular frame cross-section; the right-angled contour area of ​​the roll pressing channel 15 constitutes the target contour area.

[0028] Understandably, the first drive roller 11, the second drive roller 12, and the two driven rollers 13 together enclose a roll forming space 14 with a rectangular cross-section, which provides a precise boundary for the installation of the mandrel 25 and the forming of materials.

[0029] The length direction of the core mold 25, which is fixedly set in the roll forming space 14, is consistent with the travel direction of the rolled steel 1 in the roll forming pass 10.

[0030] The four outer peripheral sides of the mandrel 25 are respectively arranged parallel to the axes of the corresponding first drive roller 11, second drive roller 12, and two driven rollers 13, ensuring that the gap between the mandrel 25 and each surrounding roller is uniform and constant. Thus, a roll forming channel 15 with a rectangular cross-section is formed between the outer surface of the mandrel 25 and the inner surfaces of each roller. The four inner corners of this channel, formed by the corners of the mandrel 25 and the rollers, are the target contour areas that need to be filled with material.

[0031] Because the mandrel 25 is parallel to the axes of each roller, the compressive stress on the four sidewalls of the rolled steel strip 1 is extremely uniform when it passes through the rolling channel 15. This effectively avoids distortion or excessive thinning of the rolled steel strip 1 section due to uneven stress.

[0032] The radial section of the core mold 25 can be a right-angled rectangle. Compared with traditional roll forming, the right angle of the rolled steel 1 depends on the free bending and filling of the material between the rollers, which is difficult to control.

[0033] In this embodiment, the right-angled edges of the core mold 25 directly and actively abut against the pre-formed corners of the inner wall of the steel profile, working in conjunction with the external rollers to precisely define and shape the final right-angled shape like a mold. Furthermore, the rectangular frame-like channel provides the most direct and least resistant path for material flow. Driven and compressed by the drive rollers, the material is forcibly and smoothly filled into the four right-angled areas of the channel, maximally overcoming the problem of insufficient filling caused by the poor plasticity of high-strength steel.

[0034] The spacing between the core mold 25 and each roller can be flexibly adjusted based on the size of the final formed product, and there is no limitation on this.

[0035] like Figure 4 As shown, in some embodiments, the outer periphery of the core mold 25 is provided with a connecting part 26, which is used to be fixedly connected to the bracket of the driven roller 13. The connecting part 26 is provided corresponding to the open side 1.1 of the rolled edge steel 1.

[0036] Understandably, the connecting part 26 is located on the outer periphery of the core mold 25, serving as a mechanical connection mechanism between the core mold 25 and the external support structure, and is used to fix it to the frame of the driven roller 13.

[0037] The connecting part 26 is positioned corresponding to the open side 1.1 of the formed rolled steel section 1. During the rolling forming process of the rolled steel section 10, the connecting part 26 is located within the open space of the rolled steel section 1, preventing interference with the closed tube wall of the steel section. This ensures both support rigidity and maintains the integrity of the product surface. The mandrel 25 is directly fixed to the robust support of the driven roller 13, forming an integral rigid structure. This avoids vibration or displacement that may occur when the mandrel 25 is subjected to uneven rolling forces, ensuring the long-term dimensional stability of the rolling channel 15.

[0038] like Figure 5 As shown, the roll forming process also includes a motor 16, a reducer 17, a first coupling 18, a second coupling 19, a first drive mechanism 20, a second drive mechanism 21, a driven mechanism 22, a main frame 23, and a base 24. The motor 16 and the reducer 17 are used to provide a power source. The first coupling 18 and the second coupling 19 are used to transmit the driving force to the first drive mechanism 20 and the second drive mechanism 21, respectively. The main frame 23 and the base 24 serve as load-bearing components to provide support.

[0039] The main frame 23 is mounted on the base 24. The first drive mechanism 20 and the second drive mechanism 21 are spaced apart on the main frame 23. The first drive mechanism 20 is positioned further away from the base 24 than the second drive mechanism 21, while the second drive mechanism 21 is positioned closer to the base 24 than the first drive mechanism 20. Both the first drive mechanism 20 and the second drive mechanism 21 can slide on the main frame 23 to adjust the distance between them and the base 24, thereby achieving the effect of moving closer or further apart. The driven mechanism 22 is positioned between the first drive mechanism 20 and the second drive mechanism 21, and the distance between the driven mechanism 22 and the base 24 remains unchanged.

[0040] The first drive mechanism 20 includes two first frames 201 and a first drive shaft 202; Two first frames 201 are respectively spaced apart and parallel to each other on both sides of the main frame 23. The first drive shaft 202 is rotatably passed through the two first frames 201, and one end of the first drive shaft 202 is rotatably connected to the first coupling 18. The first frame 201 is connected to the main frame 23 by a tightening bolt. When the height of the first frame 201 is required, i.e. the distance between the first frame 201 and the base 24, the tightening bolt can be loosened to allow the first frame 201 to move on the main frame 23. The first drive roller 11 is fixedly mounted on the first drive shaft 202 and can rotate synchronously with the first drive shaft 202.

[0041] The second drive mechanism 21 includes two second frames 211 and a second drive shaft 212. The structure of the second drive mechanism 21 is consistent with the arrangement of the main frame 23. The second frames 211 are connected to the main frame 23 by tightening bolts. The second drive shaft 212 passes through the two spaced second frames 211 and is rotatably connected to the second coupling 19 at one end. The second drive shafts 212 are spaced apart and parallel to each other. The second drive roller 12 is fixedly mounted on the second drive shaft 212 and can rotate synchronously with the second drive shaft 212.

[0042] The corresponding arrangement of the first drive roller 11 and the second drive roller 12.

[0043] It should be noted that the main frame 23 is provided with a slide rail, and the first frame 201 and the second frame 211 are provided with a slide groove. The first frame 201 and the second frame 211 are installed on the main frame 23 and are installed on the slide rail through the slide groove, thereby realizing a sliding connection.

[0044] The driven mechanism 22 includes two driven frames 221 and two driven shafts 222. The two driven frames 221 are respectively spaced apart and symmetrically arranged on both sides of the main frame 23. Each driven frame 221 is provided with a slidable shaft bracket 223. The driven shaft 222 is rotatably passed through the shaft bracket 223. The driven roller 13 is fixedly mounted on the driven shaft 222. The two ends of the driven shaft 222 extend toward the first frame 201 and the second frame 211 arranged on the same side, respectively. That is, the driven shaft 222 is perpendicular to the first drive shaft 202 and the second drive shaft 212.

[0045] The driven mechanism 22 also includes an adjustment component 224, which is connected to the driven frame 221 and can adjust the distance between the two driven rollers 13. The adjusting assembly 224 may include an internal threaded sleeve 2241 and a threaded rod 2242. The internal threaded sleeve 2241 is rotatably mounted on the driven frame 221. The threaded rod 2242 passes through the internal threaded sleeve 2241, and its end is fixedly connected to the shaft bracket 223 of the driven frame 221. By rotating the internal threaded sleeve 2241, the threaded rod 2242 can push and pull the shaft bracket 223 in a linear motion, so that the two driven rollers 13 move closer or further apart. The threaded rod 2242 is parallel to and spaced apart from the first drive shaft 202 and the second drive shaft 212.

[0046] like Figure 6 As shown, two support beams 225 are provided between the two driven frames 221. The two support beams 225 are spaced apart along the traveling direction of the rolled steel 1. There are two connecting parts 26 of the core mold 25, which are spaced apart along the length direction and are fixedly connected to the support beams 225 respectively, so that the core mold 25 is fixedly connected to the driven frame 221 of the driven mechanism 22.

[0047] like Figure 1 As shown, in some embodiments, at least one roll forming pass 10 includes a first forming pass 30, a second forming pass 40, and a third forming pass 50. Along the traveling direction of the rolled steel section 1, the first forming pass 30, the second forming pass 40 and the third forming pass 50 are arranged in sequence, and the rolling space 14 inside the first forming pass 30, the second forming pass 40 and the third forming pass 50 gradually decreases.

[0048] Understandably, in order to process the rolled steel section 1 from pre-forming to finishing, multiple forming passes are connected sequentially to rationally distribute the total deformation and achieve progressive processing.

[0049] The roll forming process 10 includes at least three forming processes, with the first forming process 30, the second forming process 40 and the third forming process 50 arranged sequentially along the traveling direction of the rolled steel 1, forming a continuous production line.

[0050] In the first forming pass 30, the second forming pass 40, and the third forming pass 50, the internal rolling space 14 gradually decreases. This gradual decrease in the rolling space 14 can be achieved by gradually reducing the interval between the first drive roller 11 and the second drive roller 12, as well as the interval between the two side rollers. The internal mandrel 25 remains unchanged in size and serves as a rigid liner, filling the interior of the rolled steel section 1. When external rollers apply pressure, the mandrel 25 immediately provides a reaction force of equal magnitude and opposite direction, effectively suppressing any tendency to deform inward and ensuring the stability of the cross-sectional shape.

[0051] In some embodiments, the distance between the first drive roller 11 and the second drive roller 12 of the first forming pass 30 is a first height distance, and the distance between the two driven rollers 13 of the first forming pass 30 is a first width distance. The distance between the first drive roller 11 and the second drive roller 12 in the second forming pass 40 is the second height distance, and the distance between the two driven rollers 13 in the second forming pass 40 is the second width distance. The distance between the first drive roller 11 and the second drive roller 12 in the third forming pass 50 is the third height distance, and the distance between the two driven rollers 13 in the third forming pass 50 is the third width distance. The first height spacing is greater than the second height spacing, and the second height spacing is greater than the third height spacing; The first width spacing is greater than the second width spacing, and the second width spacing is greater than the third width spacing.

[0052] Understandably, in order to achieve gradual refinement of the cross-sectional dimensions of the rolled steel section 1, the distance between the drive roller and the driven roller 13 in each pass is precisely controlled so that the first forming pass 30, the second forming pass 40 and the third forming pass 50 constitute a progressive forming sequence.

[0053] Since this system is used to process right-angled rolled steel sections 1 made of high-strength steel and stainless steel, which have inherent characteristics of high yield strength ratio and poor plasticity, a progressive forming sequence is constructed using the first forming pass 30, the second forming pass 40, and the third forming pass 50. This sequence distributes the total deformation of the pre-formed rolled steel section 1 across the three passes, ensuring that the material experiences only small, controllable plastic strain in each pass. This allows time and space for material flow and strain redistribution, avoiding local strain concentration. The progressive forming method allows the material to flow more smoothly from non-critical areas (such as straight edges) to the high-strain-demand right-angle regions, rather than relying on extreme stretching of the material in the right-angle regions to fill them, thus fundamentally suppressing the tendency for local thinning and cracking.

[0054] The high yield strength ratio of the material results in a high yield point and a relatively constant elastic modulus. After unloading, the elastic strain energy stored in the part is released, producing a huge rebound.

[0055] The rolling space 14 within the first forming pass 30, the second forming pass 40, and the third forming pass 50 gradually shrinks. The forming and springback of each pass is a process of stress release and redistribution. Subsequent passes perform secondary forming based on the previously formed shape, which is not only a correction of the geometry, but also a continuous adjustment and homogenization of the internal residual stress.

[0056] The first forming pass mainly plays a guiding role, initially establishing the cross-sectional shape and guiding the material to begin flowing towards the right-angle region; The second forming pass acts as a constraint, further compacting the material, forcibly filling the corners, and controlling springback; the third forming pass acts as a finishing pass, finally calibrating the cross-sectional dimensions, so that the processed product conforms to the processing dimensions.

[0057] In this embodiment, the first height can be 158.5mm and the first width can be 58.5mm; the second height can be 156.5mm and the second width can be 56.5mm; the third height can be 153.5mm and the third width can be 53.5mm.

[0058] like Figure 1 As shown, in some embodiments, a drive guide pass 60 is also included, which is located in front of the roll forming pass 10 along the direction of the rolled steel 1.

[0059] Understandably, the drive guide pass 60 is used to provide initial kinetic energy and guidance for the movement of the rolled steel section 1 towards the forming pass. The specific structure of the drive guide pass 60 is similar to that of the first forming pass 30, and it can also include a first drive roller 11, a second drive roller 12, and a driven roller 13. The difference is that the drive guide pass 60 does not have a mandrel 25 inside. The distance between the first drive roller 11 and the second drive roller 12 of the drive guide track 60 is 160 mm, and the distance between the two driven rollers 13 of the drive guide track 60 is 60 mm.

[0060] like Figure 1 and Figure 7 As shown, in some embodiments, a heating unit 70 is also included, which is disposed between the drive guide pass 60 and the roll forming pass 10, for heating the corner area of ​​the rolled steel 1.

[0061] Understandably, the heating unit 70 is used to heat-treat the corner area of ​​the rolled steel 1 after initial positioning and guidance and before entering the roll forming pass 10, thereby selectively and locally heating the corner area of ​​the rolled steel 1 during its movement.

[0062] The heating unit 70 includes a heating frame 71 and a heating element 72. The heating frame 71 is fixedly disposed between the drive guide pass 60 and the roll forming pass 10. The heating element 72 is disposed on the heating frame 71 and is positioned corresponding to the corner of the rolled steel 1 to rapidly and locally heat the right-angle area to be formed. This increases the material temperature in the target area, significantly reduces the yield strength, and greatly improves the plastic deformation capacity. The heated corner material becomes "softer," making it easier to generate plastic flow in subsequent roll forming, thus completely solving the problem of incomplete corner filling or microcracks caused by the poor plasticity of high-strength steel. The elastic modulus of the material decreases in the hot state, and the springback during the cooling process after forming in a warm state is much smaller than that in cold forming, ensuring extremely high right-angle accuracy and dimensional stability. Furthermore, because the corner material is softened, the required rolling force is significantly reduced, thereby reducing the strength and rigidity requirements of the drive system, rolls, and mandrel 25, helping to extend the service life of the equipment and reduce energy consumption.

[0063] Selecting local heating keeps the non-formed areas of the steel profile (such as the side walls and bottom) at room temperature, preserving the strength gained from cold work hardening, thereby achieving the effect of local high plasticity and overall high strength of the rolled edge steel profile 1.

[0064] The heating element 72 can be heated by laser or contact resistance thermometer. In this embodiment, laser heating is used. A rectangular heating frame 71 is selected, and laser heating devices are set at the four right corners to heat the corner of the rolled steel 1 to a temperature range of 650℃-950℃.

[0065] like Figure 1 and Figure 8 As shown, in some embodiments, a temperature measuring unit 80 is also included, which is located between the heating unit 70 and the roll forming pass 10.

[0066] Understandably, the temperature measuring unit 80 is used to detect the heating temperature of the corner area of ​​the rolled steel 1 in real time. By monitoring the actual temperature of the corner area after heating online in real time, it provides a closed-loop feedback signal to the heating unit 70 to ensure that the corner material is always in the optimal plastic forming temperature range.

[0067] The temperature measuring unit 80 can be a non-contact infrared thermometer or thermal imager, which is fixed between the heating unit 70 and the roll forming pass 10 by the mounting bracket 82. The detection end 81 of the temperature measuring unit 80 is facing the corner area of ​​the rolled steel 1. The temperature measurement signal is transmitted to the control system in real time, compared with the preset temperature range, and the power output of the heating unit 70 is automatically adjusted.

[0068] like Figure 1 As shown, in some embodiments, it further includes a cutting unit 90, which is located behind the roll forming pass 10 along the traveling direction of the rolled steel section 1.

[0069] Understandably, the cutting unit 90, as the terminal actuator of the right-angle rolled steel profile 1 forming system, cuts the continuously formed profile to a fixed length to obtain the finished product of the final size.

[0070] The flying saw driven by a servo motor enables the entire cutting unit 90 to move in perfect synchronization with the moving steel section on the track, achieving dynamic cutting. The cutting unit 90 is a technology well known to those skilled in the art, and will not be elaborated on here.

[0071] like Figure 1 As shown, in some embodiments, two conveying units 100 are also included, with at least one roll forming pass 10 located between the two conveying units 100.

[0072] Understandably, the conveying unit 100 serves as a stable support unit before and after the forming section of the rolled steel 1, including a frame and rollers. Multiple rollers are evenly arranged on the frame to support the rolled steel 1 and ensure the continuity and stability of the forming process.

[0073] In a second aspect, this application provides a method for forming right-angle rolled-edge steel, applicable to the right-angle rolled-edge steel forming system proposed in the first aspect, comprising: Obtain pre-formed rolled steel section 1; Heating the corner of the rolled steel section 1; The heated rolled steel 1 is passed through multiple roll forming passes 10 in sequence. A core mold 25 is provided in the roll forming space 14 inside the roll forming pass 10, and the core mold 25 supports the inner wall of the rolled steel 1. Along the traveling direction of the rolled steel section 1, the rolling space 14 within the multiple roll forming passes 10 gradually decreases.

[0074] Understandably, pre-formed rolled steel section 1 is provided, such as Figure 9 As shown, the rolled steel section 1 has an open side and non-right-angled corners. It can be directly obtained through existing cold rolling processes. The material is high-strength steel, ultra-high-strength steel, or stainless steel, with a yield strength range of 600MPa-1400MPa and a thickness range of 1mm-10mm. The corner region of the rolled steel section 1 is selectively heated by the heating unit 70; the heated rolled steel section 1 then passes through multiple roll forming passes 10, wherein a mandrel 25 is provided in the roll forming space 14 of each roll forming pass 10, and the mandrel 25 provides rigid support to the inner wall of the rolled steel section 1; wherein, along the traveling direction of the rolled steel section 1, the roll forming space 14 inside the multiple roll forming passes 10 gradually decreases, realizing progressive precision forming of the steel section cross-section, such as... Figure 10 As shown, this yields right-angled rolled steel sections.

[0075] The above method also includes guiding and tensioning the rolled steel 1 by driving the guide pass 60 before the rolled steel 1 enters the roll forming pass 10; and monitoring the heating temperature of the corner area in real time by the temperature measuring unit 80 located downstream of the heating unit 70. After the rolled steel section 1 has completed all roll forming passes 10, the formed steel section is cut to a fixed length by the cutting unit 90.

[0076] This method significantly improves the plastic deformation capacity of high-strength steel by selectively heating the corner regions, effectively solving the problems of insufficient filling and cracking in the right-angle areas. Employing a progressive forming process, it achieves precise control of material springback through a gradually decreasing roll forming space 14 combined with the rigid support of the mandrel 25. The continuous inner wall support of the mandrel 25 effectively prevents tube wall collapse and cross-sectional distortion. This method, through the organic combination of thermo-coupling and progressive forming, achieves high-precision, high-quality forming of the right-angle rolled steel section 1 while ensuring production efficiency.

[0077] Based on actual production, in some embodiments, HC420LA low-alloy high-strength steel is used as the raw material. A pre-formed rolled steel section 1 with dimensions of 160mm × 60mm, a wall thickness of 2mm, an outer corner radius of 4mm, and an inner corner radius of 2mm is obtained using a traditional cold roll forming process. The laser heating temperature is set to 750℃, and the feed speed is 8m / min. The section is formed by three roll forming passes (10 rolls) and constrained by a mandrel (25). The first height and first width of the first forming pass 30 are 157.45mm × 57.2mm, respectively. The second height and second width of the second forming pass 40 are 155.4mm × 55.3mm, respectively; the third height and third width of the third forming pass 50 are 153.63mm × 53.27mm, respectively.

[0078] The final product is a right-angle rolled steel section 1 with dimensions of 153.63mm × 53.27mm, an inner corner radius of 2mm, and an outer corner radius of 0.2mm. The springback is reduced by about 40%, making it suitable for building curtain wall structures.

[0079] In some embodiments, the raw material is HC550 / 980QP ultra-high strength steel. The pre-formed rolled steel section 1 has an outer dimension of 160mm × 60mm, a wall thickness of 2.5mm, an outer corner radius of 5mm, an inner corner radius of 2.5mm, a laser heating temperature of 800℃, a feed speed of 5m / min, and is formed by three roll forming passes 10 and constrained by the mandrel 25. The first height and first width of the first forming pass 30 are 158.5mm × 58.5mm, respectively; the second height and second width of the second forming pass 40 are 156.5mm × 56.5mm, respectively; and the third height and third width of the third forming pass 50 are 153.5mm × 53.5mm, respectively. Ultimately, a right-angle rolled steel section 1 with dimensions of 153.49mm × 53.49mm, an inner corner radius of 2.5mm, and an outer corner radius of 0.3mm was obtained, with the corner thickness increased by approximately 12%. The finished product met the precision requirements for automotive reinforcement parts.

[0080] In some embodiments, the raw material is 304 stainless steel, and the pre-formed rolled steel section 1 has an external dimension of 160mm × 60mm and a wall thickness of 1.2mm. The outer corner radius is 2.4mm, the inner corner radius is 1.2mm, the laser heating temperature is set to 650℃, and the feed speed is 10m / min. It is formed by three rolling processes (10 rolls) and constrained by the mandrel 25. The first height and first width of the first forming pass 30 are 157.5mm × 57.5mm, respectively; the second height and second width of the second forming pass 40 are 155.5mm × 55.5mm, respectively; and the third height and third width of the third forming pass 50 are 153.27mm × 53.67mm, respectively. Ultimately, a right-angle rolled steel section 1 with dimensions of 153.27mm × 53.67mm, an inner corner radius of 1.2mm, and an outer corner radius of 0.4mm was obtained. It has no cracks at the corners, good weldability, and is suitable for building railing structures.

[0081] 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.

[0082] 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.

[0083] 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 rolled-edge steel forming system, characterized in that, include: At least one roll forming pass; The roll forming process includes a first drive roller, a second drive roller, and two driven rollers; The first drive roller and the second drive roller are spaced apart and arranged in parallel, and the two driven rollers are spaced apart and arranged in parallel. The first drive roller and the second drive roller are arranged between the two driven rollers to enclose and form a roller pressing space. The core mold is fixedly disposed within the rolling space. The core mold is spaced apart from the first drive roller, the second drive roller, and the two driven rollers to form a rolling channel for the rolled steel to pass through. The core mold is used to form a rigid support for the inner wall of the rolled steel section, and works in conjunction with the first drive roller, the second drive roller and the two driven rollers to apply pressure, so as to guide the material of the rolled steel section to fill the target contour area of ​​the roller pressing channel, thereby forming a preset cross-sectional contour of the rolled steel section.

2. The right-angle rolled-edge steel forming system according to claim 1, characterized in that, The first drive roller, the second drive roller, and the two driven rollers together form a roll pressing space with a rectangular cross-section; The outer peripheral side surface of the core mold is arranged parallel to the axes of the corresponding first drive roller, second drive roller and two driven rollers, thereby forming the roll pressing channel with a rectangular frame cross-section; The right-angled contour region of the roller pressing channel constitutes the target contour region.

3. The right-angle rolled-edge steel forming system according to claim 2, characterized in that, The outer periphery of the core mold is provided with a connecting part, which is used to fix and connect with the bracket of the driven roller; The connecting part is provided corresponding to the open side of the rolled edge steel.

4. The right-angle rolled-edge steel forming system according to claim 1, characterized in that, At least one roll forming pass includes a first forming pass, a second forming pass, and a third forming pass; Along the traveling direction of the rolled steel section, the first forming pass, the second forming pass, and the third forming pass are arranged sequentially, and the rolling space inside the first forming pass, the second forming pass, and the third forming pass gradually decreases.

5. The right-angle rolled-edge steel forming system according to claim 4, characterized in that, The distance between the first drive roller and the second drive roller in the first forming pass is a first height distance, and the distance between the two driven rollers in the first forming pass is a first width distance. The distance between the first drive roller and the second drive roller in the second forming pass is the second height distance, and the distance between the two driven rollers in the second forming pass is the second width distance; The distance between the first drive roller and the second drive roller in the third forming pass is the third height distance, and the distance between the two driven rollers in the third forming pass is the third width distance. The first height spacing is greater than the second height spacing, and the second height spacing is greater than the third height spacing; The first width spacing is greater than the second width spacing, and the second width spacing is greater than the third width spacing.

6. The right-angle rolled-edge steel forming system according to claim 1, characterized in that, Also includes: The driving guide pass is located in front of the roll forming pass, along the direction of the rolled steel section.

7. The right-angle rolled-edge steel forming system according to claim 6, characterized in that, Also includes: A heating unit is disposed between the drive guide pass and the roll forming pass, and is used to heat the corner area of ​​the rolled steel section.

8. The right-angle rolled-edge steel forming system according to claim 7, characterized in that, Also includes: A temperature measuring unit is located between the heating unit and the roll forming pass.

9. The right-angle rolled-edge steel forming system according to claim 7, characterized in that, Also includes: The cutting unit is located behind the roll forming pass, along the traveling direction of the rolled steel section.

10. A method for forming right-angle rolled steel sections, characterized in that, The right-angle rolled steel forming system as described in any one of claims 1-9 includes: Obtain pre-formed rolled steel sections; Heating the corner of the rolled steel section; The heated rolled steel is passed through multiple roll forming passes in sequence. A core mold is provided in the roll forming space inside each roll forming pass, and the core mold supports the inner wall of the rolled steel. Along the traveling direction of the rolled steel section, the rolling space within the multiple rolling forming passes gradually decreases.

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