Grooved Roll Forming Raised Lines Metal Sheet
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Solution Overview
Problem
Existing methods for producing structural components with raised lines are inefficient, requiring separate welding of reinforcing plates, which increases manufacturing costs and does not provide uniform reinforcement throughout the component.
Innovation Solution
A metal sheet production method using a rolling mill with a grooved roll that forms raised lines on the surface, allowing for the creation of a metal sheet with bilaterally symmetric, rectangular, trapezoidal, or V-shaped grooves, which can be used to produce a structural component with reinforced areas without the need for separate welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing plates are welded to the structural component to increase strength, then the strength is improved at specific locations, but the manufacturing cost increases and the reinforcement is not uniform throughout the component
Solution Approach 1:
The invention applies preliminary action by forming raised lines (protruding ridges) on the metal sheet during the rolling process before the pressing operation. This pre-reinforcement is created by passing the metal sheet through grooved rolls that impart the desired geometric features, eliminating the need for subsequent welding of reinforcing plates and reducing manufacturing complexity.
Solution Approach 2:
The invention merges the reinforcement function directly into the metal sheet by creating raised lines through the rolling process. Instead of using separate reinforcing plates that require welding, the reinforcement is integrated into the sheet itself as a geometric feature, combining the sheet forming and reinforcement functions into a single process.
2Strength
If reinforcing plates are welded to the structural component, then localized reinforcement is achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The invention merges the reinforcement function directly into the metal sheet by creating raised lines through the rolling process. Instead of using separate reinforcing plates that require welding, the reinforcement is integrated into the sheet itself as a geometric feature, combining the sheet forming and reinforcement functions into a single process.
Solution Approach 2:
The invention applies preliminary action by forming raised lines (protruding ridges) on the metal sheet during the rolling process before the pressing operation. This pre-reinforcement is created by passing the metal sheet through grooved rolls that impart the desired geometric features, eliminating the need for subsequent welding of reinforcing plates and reducing manufacturing complexity.
3Strength
If reinforcing plates are welded to the structural component, then reinforcement is provided at specific locations, but production time increases due to separate welding operations
Solution Approach 1:
The invention applies preliminary action by forming raised lines (protruding ridges) on the metal sheet during the rolling process before the pressing operation. This pre-reinforcement is created by passing the metal sheet through grooved rolls that impart the desired geometric features, eliminating the need for subsequent welding of reinforcing plates and reducing manufacturing complexity.
Solution Approach 2:
The invention achieves continuity of useful action by integrating the reinforcement feature creation into the continuous rolling process. The grooved rolls form the raised lines on the metal sheet in a continuous operation as the sheet passes through, eliminating discrete welding steps and maintaining continuous production flow.
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
This method enables the production of structural components with reinforced areas throughout, reducing manufacturing costs and eliminating the need for separate reinforcing members, while ensuring the structural integrity and formability of the metal sheet.
Implementation Method 1
a grooved roll is prepared, the grooved roll including, in an outer peripheral surface, one or more grooves extending in a circumferential direction
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A method for producing a metal sheet with raised lines uses a rolling mill including a plurality of roll stands and produces a metal sheet including, on an upper surface, a plurality of raised lines extending in a rolling direction. The method includes a preparing step, a choosing step, an incorporating step, and a forming step. In the preparing step, a grooved roll is prepared, the grooved roll including a plurality of grooves in an outer peripheral surface. In the choosing step, a stand at least one stage before the last stand is chosen. In the incorporating step, the grooved roll is incorporated in the rolling mill as an upper roll of the chosen, specified stand. In the forming step, a workpiece is rolled by the rolling mill and is formed into a metal sheet with raised lines formed corresponding to the respective grooves of the grooved roll. At this point, in the forming step, until a leading edge of the workpiece reaches a stand next to the specified stand, a maximum rolling reduction achieved by rolls of the specified stand is set to a provisional value that is lower than a required value. After the leading edge of the workpiece reaches the stand next to the specified stand, the maximum rolling reduction achieved by the rolls of the specified stand is changed to the required value.