Cold Forming Metal Profiles for Tight Chamber Tolerances
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Solution Overview
Problem
Current methods for producing metal sections, such as mast uprights, face challenges in achieving parallel flanges with close tolerances and high material strength while maintaining weldability, resistance to brittle fracture, and low production costs, particularly in hot rolling and drawing processes.
Innovation Solution
A method and device utilizing a roll stand for cold forming previously rolled section blanks to achieve high flange parallelism, close chamber tolerances, and controlled work hardening, using high-strength inner working rolls and support bodies to apply consistent surface pressures, allowing for the use of a single roll size and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot rolling is used to produce metal sections, then production costs are low and weldability is good, but flange parallelism and chamber dimension tolerances cannot be achieved
Solution Approach 1:
The method applies preliminary cold forming action to hot-rolled section blanks before final use. By performing cold forming on the flanges after hot rolling, the invention achieves close chamber dimension tolerances and flange parallelism while maintaining the cost advantages of hot rolling. The cold forming step is a preliminary action that prepares the sections to meet strict tolerance requirements.
2Manufacturing precision
If drawing is used to produce metal sections, then flange parallelism and chamber dimension tolerances are achieved, but production effort and costs increase significantly
Solution Approach 1:
The invention segments the manufacturing process into two distinct stages: first hot rolling to achieve basic section geometry at low cost, then selective cold forming only on the flange regions requiring precision. This segmentation avoids the need for complete drawing processes, reducing production effort and costs while achieving the required chamber dimension tolerances and flange parallelism.
3Strength
If drawing is used to produce metal sections, then material work hardening is achieved, but brittle fracture resistance deteriorates
Solution Approach 1:
The invention applies local quality by performing cold forming only on specific flange regions where precision is needed, rather than subjecting the entire section to drawing. This localized cold forming provides necessary work hardening in the contact areas while preserving the ductile properties and brittle fracture resistance of the bulk material. The hot-rolled base material maintains its superior fracture resistance.
4Manufacturing precision
If multiple roll sizes are used to achieve close tolerances, then chamber dimension precision is improved, but device complexity and production costs increase
Solution Approach 1:
The invention changes the parameter of roll temperature, using cold rolls (at ambient or controlled low temperature) to form the hot-rolled sections. This temperature parameter change enables precise dimensional control and flange parallelism without requiring multiple roll sizes. The cold forming process inherently provides the necessary precision while maintaining device simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of metal sections with improved wear properties, reduced run-in freeplay, and enhanced brittle fracture resistance, while minimizing production costs and eliminating the need for multiple roll sizes, achieving favorable cost and performance outcomes.
Implementation Method 1
it is suggested to recalibrate previously rolled section blanks by rolling in the temperature range associated with cold forming
Implementation Method 2
the material zones that are exposed to substantial stresses during subsequent operation are not work hardened
Implementation Method 3
the sections can be drawn afterwards. Drawing mast sections guarantees good parallelism of the flanges, close dimensional tolerances, smooth surfaces and advantageous work-hardening of the material
Data Source
AI summary
The invention relates to a method and device for producing metal sections having two profile flanges arranged opposite one another and having flange inner faces that are to be kept apart from each other by a closely toleranced final chamber dimension. In order to adapt the chamber dimension from a starting chamber dimension K0 to a desired final chamber dimension K1, the metal section is passed through the device, which forms working gaps between an inner working roll pair and outer support rolls. The working rolls that form the inner working roll pair roll over each other in order to brace the forming forces exerted on the working roll pair from the flange inner faces against each other.