Roll Forming Dies for Variable Cross-Section Steel
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Solution Overview
Problem
Current roll forming methods are inadequate for producing shaped steel with varying cross-sectional shapes in the longitudinal direction, particularly with high tensile steel, due to complexity and stiffness issues, and require costly new facilities.
Innovation Solution
A method and apparatus using synchronized first and second rolling dies with annular ridge and groove parts of varying cross-sectional shapes, where the side surfaces of the ridge part are relieved to maintain a consistent gap with the groove part, allowing for the production of shaped steel with varying cross-sectional shapes without complex control systems and enabling sufficient material contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If press forming is used to produce shaped steel with varying cross-sectional shape, then the cross-sectional shape can be formed, but springback occurs and high tensile steel cannot be properly formed
Solution Approach 1:
The invention transitions from static press forming to dynamic roll forming, where continuous rotation of rolling dies provides progressive deformation. This dynamic process allows the material to be gradually shaped through multiple contact points, preventing springback while accommodating high tensile steel properties
Solution Approach 2:
The shaping process is divided into multiple sequential stages as the strip steel passes through successively arranged rolling dies. Each die performs a portion of the total deformation, distributing the forming action across multiple segments rather than applying it all at once, which prevents springback
2Productivity
If conventional roll forming is used, then constant cross-sectional shapes can be produced efficiently, but varying cross-sectional shapes cannot be formed
Solution Approach 1:
The rolling dies are designed with variable cross-sectional profiles along their circumferential direction, allowing them to dynamically adapt to different shape requirements while maintaining continuous rotation. This enables mass production of varying cross-sectional shapes without sacrificing productivity
Solution Approach 2:
Different portions of the rolling die circumference have different profiles, allowing each local region of the die to perform a specific shaping function. This local differentiation enables the production of varying cross-sectional shapes while maintaining continuous operation
3Adaptability or versatility
If split rolls with variable roll widths are used, then varying cross-sectional shapes can be produced, but apparatus complexity and control complexity increase significantly
Solution Approach 1:
The invention combines the shaping function and the varying profile function into a single integrated rolling die structure. The annular ridge and groove parts are merged into one component that performs both functions simultaneously, eliminating the need for separate width-adjustment mechanisms
4Adaptability or versatility
If split rolls with variable roll widths are used, then varying cross-sectional shapes can be produced, but control complexity increases significantly
Solution Approach 1:
The rolling dies are designed to automatically produce the desired varying cross-sectional shapes through their inherent geometry. The synchronized rotation of the annular ridge and groove parts self-generates the shape variation without requiring external control signals or active adjustment mechanisms
5Shape
If broadening roll widths of split rolls is used, then corner parts contact the material, but mill stiffness becomes insufficient for high tensile steel
Solution Approach 1:
The invention adds a circumferential dimension to the rolling die profile, creating annular ridge and groove parts that vary in cross-section around the circumference. This dimensional change allows corner formation without requiring excessive roll width, maintaining mill stiffness
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 approach simplifies the roll forming process, eliminates the need for complex control systems, and ensures sufficient contact between roll barrel parts and material, effectively suppressing mill stiffness insufficiency, even with high tensile steel, allowing for efficient production of shaped steel with varying cross-sectional shapes.
Implementation Method 1
a gap which is equal to a thickness of the sheet is formed between the first rolling die and second rolling die and the annular ridge part of the first rolling die and the annular groove part of the second rolling die engage
Data Source
AI summary
A roll forming device, for roll forming for the purpose of manufacturing shaped steel the cross-sectional shape of which varies in the longitudinal direction, is equipped with: first die rolls having an annular ridge part the cross-sectional shape of which varies in the circumferential direction; second die rolls having an annular groove part the cross-sectional shape of which varies in the circumferential direction; and a drive device for the first die rolls and the second die rolls. A gap is provided at the side surfaces of the annular ridge part of the first die rolls, across the entire circumference in the circumferential direction, such that the gap with respect to the side surfaces of the annual groove parts of the second die rolls widens inward in the radial direction.