CN101374615A

CN101374615A - Continuous process of roll-forming stamped sheet

Info

Publication number: CN101374615A
Application number: CNA2006800365752A
Authority: CN
Inventors: 戴维·W·希瑟林顿
Original assignee: Shape Inc
Current assignee: Shape Inc
Priority date: 2005-10-04
Filing date: 2006-10-03
Publication date: 2009-02-25
Also published as: US20070095001A1

Abstract

An apparatus includes a press with dies configured to deform a strip of material by drawing material primarily from a width direction, a slitter set to cut the deformed strip to a uniform desired width dimension, and a roll-former with rolls configured to shape linear portions of the deformed and now uniform-width strip into a continuous beam. The apparatus further includes a welder for welding abutting edges of the sheet together to form a permanent tube, a sweep station for imparting a longitudinal shape to the continuous beam, and a cut-off for cutting the continuous beam into segments useful as vehicle bumper beams. A controller controls timing of various components. The beam segments are optimized in specific regions for local strength and minimized weight, and features can be incorporated into the beam segments such as coplanar mounting surfaces.

Description

The continuity method of roll-forming stamped plate

The cross reference of related application

This is the sequence number of submitting on February 11st, 2,006 11/330, the patent application of 301 common transfer, while pending trial, title is the part continuation application of " the difform continuity method of roll forming pre-punching ", the temporary patent application sequence number of submitting on October 4th, 2,005 60/723 is also enjoyed in this patent application, 393, title is the rights and interests of " the difform continuity method of roll forming pre-punching ".

Background technology

The present invention relates to the difform continuity method of roll forming pre-punching, more particularly, relate to and a kind of punching press/deformation method being combined with roll forming apparatus so that obtain the method for the two advantage in continuity method.

Roll forming is become be used for the preferable production process of many hatch frame shaped steel and tubular structure shaped steel with the roll forming advantages associated.Automotive bumpers beams is an example of product, and that the benefit of described product utilization roll forming is produced is in light weight, cost is low and based on the design of performance, described design extensively is accepted and uses commercial.Roll forming formula pilot beam is represented most of pilot beam market, and continues to obtain to popularize as the pilot beam from category-A surface design such as punching press and chromium plating beam to structural beams, and the said structure beam is positioned at the back of plastics stringcourse (fascia).The another kind of pattern of buffer is open section (being called " C " section buffer sometimes), also is used for bumper beam designs usually.These open sections require other secondary operations usually, so that insert and weld internal partition and the strapping that is placed on key place.The use of dividing plate and strapping is a structural intergrity of improving section under the situation of adding minimum weight.These dividing plates and strapping have improved the bending stiffness of open section, and are issued to the performance of this increase in the sacrifice secondary operations.

Roll forming has many benefits, and this makes it become the method for the low-cost Guan Liang of manufacturing.Some advantage of roll forming comprises the ability of shaping high strength steel and unimach (UHSS).Before roll forming, can on smooth section of sheet material material, use pre-punching, middle perforation and/or back perforation procedure.In addition, certain operations can be connected with roll forming and be carried out, as series connection welding and cut-out.Yet roll forming has limitation, as not changing material property in the parts and can not changing the cross section along the length of parts.Can not change the cross section along the length of parts and not cause usually in some do not need to satisfy the zone of performance requirement and use too much material, above-mentioned performance requirement needs in other zones.Too much material also is added on the weight and material cost of parts.Say that exactly test and Computer Analysis show, the Guan Liang that is limited in its two ends place and is positioned at the center will show a free body barrier film, and section depth (that is the moment of inertia) is big more herein, and is then hard more at the beam of the center of beam generation.The cross section that can not change it along the pipe beam of roll forming causes Guan Liang to have constant the moment of inertia.Constant the moment of inertia causes in material excessive in the zone of the length of Guan Liang and the geometry total bending stiffness to beam and does not exert an influence.

Pressing has the advantage that is better than roll forming and is to make the beam with irregular cross section.Yet punching operation is restricted, and compare general efficient with roll forming lower, because each slab material must move on the side direction and accurately locate each die stroke after.In addition, mould can not be made Guan Liang under the situation that is provided with quite big difficulty or complexity, perhaps have secondary operation.In addition, high strength and superhigh intensity sheet material material are easy to die wear, and the degree of wear depends on the warpage amount of giving the sheet material material, and depend on the intensity of material.

It should be noted, present roll forming utilized the quick acting stamping machine of low power sometimes before roll forming, but these press be at material smooth and utilize roll forming component processing is shaped before with perforation such as some bodies such as hole, slit with cut into material.

Typically (great majority) stamping machine method of being used for form metal can be referred to as the cold punching platen press.In the cold punching platen press, material is to be shaped between mould, and material and mould are general simultaneously keeps at room temperature.Another kind of shaping type is called hot stamped process.In hot stamped process, with the austenitic temperature (Ac of METAL HEATING PROCESS to it ₃), in mould, finish the quick cooling after the shaping then.For making required austenitic temperature of material quenching and time depend on the chemical composition and the chemical property of material, reach desirable final performance.For example, known is that the steel of 0.2% mass percent of carbon containing is heated to 850 ℃ (or higher as 880 ℃ to 950 ℃), so that reach their austenite region, then they are forwarded to the mould that is cooled in the stamping machine that is used for being shaped, and steel are still enough warm simultaneously.Hot steel are shaped with punch die, are cooled off fast by the temperature of mould and/or by the water quenching then.For example, material can remain in the mould under press is in its situation of full stroke position, until steel reach enough low temperature when keeping the desirable strength of materials till.Yet, the process of a kind of often batch (-type) of above-mentioned drop stamping technology " stop after again go ", this does not think in history use (that is extremely not being suitable for using with the roll forming apparatus series connection) in the continuity method that is very suitable for operating under higher linear velocity.In addition, I, i.e. the inventor for above-mentioned reasons, does not know combining of any punching press and roll forming.

Therefore, wish a kind of system that has above-mentioned advantage and address the above problem.

Summary of the invention

In one aspect of the invention, the equipment of buttress brace of being suitable for being shaped comprises a press and cooling system, above-mentioned press has some moulds, described mold arrangement becomes by drawing and mobile material is deformed into the distortion band with 3D shape with the smooth band of thermometal material, and above-mentioned cooling system is relevant with press, and is configured to the metal material through heating of the band of cooling strain.Roll former is positioned at the downstream of press and cooling system, and has some rolls, and described roll configuration becomes the marginal portion of the band that will be out of shape to be processed into continuous beam shape.

In another aspect of this invention, the equipment of the buttress brace that is suitable for being shaped comprises heater, and described heater configuration becomes steel are heated to temperature at least about 850 ℃.Press comprises some moulds, and described mold arrangement becomes to make the continuous band distortion of hot steel.Cooling system and press are associated, and are used for quenching and hardening heat steel.The downstream that roll former is connected and is provided with and is positioned at cooling system with press, and have some rolls, described roll configuration and be mounted to the band of reception towards direction of feed, and the marginal portion of the band of distortion is processed into buttress brace shape.

In another aspect of this invention, method comprises the step of the steel plate that drop stamping is heated, and above-mentioned plate has first tensile strength, and above-mentioned steps comprises drawing and expanded material.Method also comprises the plate of quenching punching press, so that make material have higher tensile strength.Method also comprises utilizes the some parts roll forming Cheng Liang of roll former with the plate of punching press.

In another aspect of this invention, the method for shaping buttress brace may further comprise the steps: heater is provided; Press is provided, and described press comprises a plurality of shaping dies, and cooling system also is provided, and above-mentioned shaping dies is in the heater location downstream, and above-mentioned cooling system is associated with press; With roll former is provided, described roll former has some rolls, roll is shaped and connects (in-line) with press and in the downstream of press.Method comprise heating material band, operation mould in case by draw hot material and thereafter fast coolant make the roll of distortion of material band and operation roll former so that receiving the band on the direction of feed and the marginal portion of the band of distortion is processed into buttress brace shape.

Inventive concept concentrates on the tubular sections, but should be noted that above-mentioned thought and uniqueness thereof also can be applied to open section.

These and other aspect of the present invention, purpose and characteristics will be understood and be understood when research the following describes book, claims and accompanying drawing by those skilled in the art.

Description of drawings

Fig. 1 is the flow chart that embodies method of the present invention.

Figure 1A is the side view that comprises the equipment that comprises roll former, punching press workshop section, welding bay and bending (sweeping) workshop section of the method that is used for Fig. 1.

Fig. 2 is a side view of using automotive bumpers beams of the present invention.

Fig. 3-the 6th passes the side view that Fig. 2 gets.

Fig. 7 is that automotive bumpers beams is after roll forming but the side view before the bending in the vertical.

Fig. 8 is the end-view that the beam of Fig. 7 passes exemplary roll forming workshop section, and this illustrates beam, roll and welding point.

Fig. 9-9A is respectively flow chart and the side view that is similar to the corresponding machine of Fig. 1 and 1A, but is applicable to drop stamping sheet metal material before the roll forming part of machine.

The specific embodiment

The present invention limits by the high-strength plate material, as the material that surpasses 80ksi tensile strength with even surpass the unimach (abbreviating " UHSS " or " AUHSS " material sometimes as) of 140ksi tensile strength, the method for producing the Guan Liang of rollforming with variable cross section.For example, DP 980 (DF 140) material successfully uses.The ability that changes the cross section along the length of beam reaches by combining with the rolling and forming method via the pre-shaping method of pressing.The operation of pressing and rolling and forming is series connection and carrying out continuously.Do not need the series connection continuity method of after-treatment to obtain the very low autofrettage of a kind of cost.Utilize stamping machine to come, and before material passes the roll forming instrument, add some bodies (features) to the material preform and with the punching in advance of sheet material material.When material when being flat, stamping material produces a kind of shape, and described shape has the different degree of depth and geometry across the length of punch components.For example, the shape of shaping can be represented the section backward of pipelined buffer section.The stamping machine that the various bodies of punching press are combined with the shaping difformity has than usually body being stamped into the bigger tonnage of pre-punching machine in the material.This stamping machine also must be included in punch die and the necessary button of punching press body outside the required punching.Supposition one-shot punching operation is used for making the pipelined buffer system because it is contemplated that the material rate such as the UHSS material that are higher than mild steel, so must be enough to form shape.More senior material such as UHSS stand quite a large amount of work hardening, repeatedly impact producing desirable net shape if desired, and then work hardening makes material be easy to crack.If pressing requires a large amount of the shaping, and makes the sizable work hardening of material production again, then the shape of punching press is to be shaped in the one-shot operation probably, and avoiding any material crack, described crackle may be by the material production of punch process sclerosis repeatedly.If the speed of noting being shaped is to keep the work hardening minimum, then can accomplish by initiatively (aggressive forming) shaping of punching press with many impacts.When punching press UHSS, should the fine application of understanding the design criteria of relative bending radius.Should also be noted that material mainly is to be shaped by mobile material rather than by stretching or extrded material when with the UHSS material forming.Some materials such as UHSS have high-yield strength and tensile strength, and have low percentage elongation again.Low elongation directly is transformed into low ductility, described low ductility no thoroughfare material attenuate, that is extruding/drawing is shaped.

Being used for the material of shaping form during pressing draws from the width of coiled material, and does not draw along coiled material.This width that will require to supply with the coiled material of stamping machine surpasses certain size, so that can be used for by the drawing shape, and still provides enough blank width to be used for the roll forming operation, utilizes described roll forming to operate shape is finish-machined to tubular geometry.It is also conceivable that at the place, two ends of the shape that is shaped and to add venting seam (relief slot).These seams help to pressurize to material from the edge of blank width, and do not pressurize along the length of the shape that has been shaped.Venting seam also keeps blank before striking out the shape of each parts and afterwards without the blank flatness of the non-deformation zone of crossing punching press.Because material moves across web width, so the shaping operation in press will produce the blank of irregular widths, and must be varying sized before material can pass roll former.Roll forming utilizes the edge of material to guide and material for trapping by rolling pass to material, and carries out bending at each rolling pass place simultaneously.The varying sized of blank width can be carried out in one or more positions along manufacture process.It is contemplated that irregular blank cuts immediately after leaving stamping machine.Cutting operation may be offset, and herein with an edge slit, and cuts another edge as the benchmark edge then.Material also can cut after early stage one or more rolling passes of roll forming machine operation.It is contemplated that with before cutting the operation change size and before roll forming finishes, some shaping originally of beginning has some advantage in roll former at irregular blank.Other selection scheme is to give irregular blank varying sized in a workshop section of multiplex's section punching operation.A kind of selection scheme is that the bottom (bed) of stamping machine is at least two times of representative partial-length, and perhaps another selection scheme is to utilize two series connection press.It is contemplated that, the venting seam that first workshop section of stamping machine or the first press punching press are essential in the place, end of part length, and form complete shape.Second workshop section of press or second press will body (hole, seam, etc..) strike out the shape of shaping, irregular material is trimmed to a size that is suitable for roll forming, and described roll forming will become the pipe beam section that has different cross-sectional geometry along the length of this part to the parts finishing.

Because the required shaping amount of parts may build-up materials after press and before the roll forming.In typical pre-punching operation, be that various bodies are added on the smooth material herein, mould is constituted to become with material advance (that is portable pre-punching mould (flyingpre-pierce die)).Preferably, described finishing die is configured when mobile with the material that moves in the vertical and carries out punching press, that is the preparation that moves moulds.Alternatively, if the shape finishing die is too heavy so that can not move with material, then may be press after with roll forming before build-up materials.The another kind of selection scheme that is used for overweight mould is the buildup of material of abandoning after press, and uses under the roll forming operational circumstances and stop-beginning operation.After can utilizing and stop, roll forming machine begins repeating motion again and success and motion effectively, if but adopt the series connection HFI welding, then stop-setting in motion is not very complementary method.Stop-start method may be more suitable in Laser Welding or Contact welding.

Now can be delivering in the rolling and forming method through the shape of shaping with without the blank of finishing or through the blank of finishing.The shape that the roll forming instrument will be configured to shaping provides the gap.It is contemplated that, only come to finish constant part geometry, the periphery of while support unit drawing and remaining periphery of roll forming by roll forming with top roll instrument.It is contemplated that the degree of depth of the shape of shaping and shape itself changes along the length of parts.In the position of some regulation, and most preferably near the width of the position transition portion between the section of the section of drawing and roll forming keeps invariable along the length of parts.This common width is important, because it provides a position, and when all the other materials are shaped in roll forming, can be in this position constraint material.Along with roll forming is proceeded, the ability of the parts that constraint is shaped will lose efficacy, because at some the some place along roll forming, each leg of parts will be referred to form tubular form.At this moment, internal mandrel has the shape that must retrain by the punching press formed thereby, and finishes tubular geometry with roll forming.

Each leg of described parts takes contact point to by roll forming, and is at this moment that two independent legs are soldered, to form the one-piece tubular parts that have different cross sections along the length of described parts.Welding can in all sorts of ways and carry out, and the type of used welding is based on many factors, that is geometry, desirable circulation timei etc...Be used to weld the laser weld that selection scheme can comprise HFI welding, contact welding or be used for tubular sections.Other welding selection schemes such as impulse seam weldering (rotary spot welding), plasma arc welding (PAW) or laser weld may be more suitable in erose geometry.All these welding methods all are extensive use of at present, so that produce commercially available tubulose and irregular shape with constant cross section.

Automotive bumpers beams requires curvature to a certain degree usually, and described curvature is replenished the moulding of automobile, and along with moulding changes and the more active that becomes, the pilot beam with a plurality of radiuses becomes and is easy to be packaged in the available crust.In making pilot beam, have a plurality of radiuses and be referred to as compound swept bumper.This series connection and in manufacture process the ability of production compound swept bumper beams can realize that described equipment is driven and computerizeds control with the equipment that uses servo control mechanism.This type equipment can be for regulating bending roll in real time, and described bending roll is used for making beam to have curvature.Owing to regulate in real time bending roll, so can have a plurality of radiuses at assigned position place along the length of beam.Last serial operation (in-line operation) is to cut the beam section to Len req.Rupturing operation can be carried out in various manners.The most frequently used method that pilot beam is cut to Len req is mobile cut-out equipment.Mobile cut-out equipment will be advanced with described parts, and carry out rupturing operation when parts move with linear velocity.Typical mobile cut-out equipment comprises that parts clamp punching block (clamping steel forms), air or hydraulic cylinder and shear-blade.

Uniqueness of the present invention is to produce along the length of described parts to have the single piece body roll forming structural beams in different cross sections or the ability of open section roll forming structural beams.Under the roll forming situation, the ability that changes the cross section along the length of beam is to reach by shaping dies and stamping machine that utilization is positioned at upstream and series connection.The design of the novelty of rolling instrument makes coplanar flat edge section that the preform shape of punching press can freely move it by each roll forming rolling pass, and does not have the distortion forming shape change of central segment of its present drawing.Each rolling pass of roll forming continues to carry out, so that the material forming of edge section is become to comprise the net shape that is stamped and is shaped.The present lower power of roll forming utilization, QA stamping machine before roll forming, but these press are to be used for punching such as body such as hole, seam and to cut in the smooth material, and before roll forming, be used for making parts to be shaped.The present invention has increased the tonnage of upstream stamping machine, and shaping dies is joined in the stamping machine.Use one or more stamping machine to form described steel with definite shape, described shape produces the pipe beam section that has different cross sections along the length of described parts when being closed into geometry with roll forming.Same thought can be used for open section, herein punching operation make have across part length irregularly shaped, and the remainder of the described component shape of roll forming operation processing.Changing the cross section along part length provides and has effectively utilized the chance that material and geometry reach performance requirement.The result is the weight of the continuous low-cost autofrettage production of a kind of usefulness and the structural member of performance optimization.

Fig. 1 illustrates the flow chart of using method of the present invention, and Figure 1A illustrates corresponding apparatus.Scheme the above, method is from step 30 (Fig. 1), herein with coiled sheet 31 (Figure 1A) debatching, and the band plate/plate 32 of debatching sent forward.This method advances to step 33, so that pass through to use stamping machine 34, and plate 32 is carried out pre-punching and shape shaping, and above-mentioned stamping machine 34 drives

moulds

35 and 36 and withstands plate 32 together.Press 34 and/or

mould

35 and 36 preferably can move on side direction with plate 32 during the pressing, and are actions faster.Alternatively, roll forming can slow down or stop during operating in

punching operation.Mould

35 and 36 configurations and be designed to the pressed sheet material mainly are simultaneously the widths of slave plate 32 rather than from longitudinal direction pulling and mobile material.Should be noted that preferable material is unimach (UHSS), described UHSS can be crooked, but can not draw or stretch.Therefore, when using the UHSS material, (rather than in the vertical) pulling and mobile material are important thought on side direction.During the 3 D deformation method of step 33, can utilize in the plate at (following) each end place of bumper section rip cutting to reduce the lengthwise movement of sheet material material.

Method advances in step 38 by cutting machine (slitter) 39, and described cutting machine is with the edge rip cutting of the plate 32 that is shaped/be cut to a specific known width dimensions, and the marginal portion of plate 32 still is in the coplanar flat state simultaneously.

Then, method advances in step 41 by the roll forming operation, and roller mill 42 has the 43-48 ' of roll forming workshop section as shown in the figure.The roller mill 42 that specifically illustrates has some rolls, it is configured to plate is shaped as the tubular form (see figure 7), described tubular form is located to weld and 82 places, position welding in welding bay 53 (Figure 1A) in the edge 51,52 (Fig. 8) of butt joint in method step 50.In the place of needs or hope, internal mandrel can be arranged on upstream or downstream, so that help to keep transverse shape, perhaps provides support for operating crooked or be shaped by roll forming.For example, internal mandrel can be fixed on 54 places, position, and one fixedly tie-rod or rope can be in the downstream (or upstream) extend so that the mandrel support is provided.Because punching operation, the centre in cross section or lower part change shape in the vertical with on the side direction, the final cross section that makes final beam 72 along its length in depth dimensions and change (seeing Fig. 3-6) in shape.

Method advances to step 60 then, at this place when pipe beam 61 with adjustable outer mandrel 63 reach (if necessary) internal mandrel 64 move through stable/when exciting roller 49 and crooked workshop section 62, the pipe beam 61 of crooked continuous welding in the vertical.In addition, by cut-out equipment 71 continuous beam 61 being cut in step 70 to have length to become single beam 72, and described beam 72 can be used as small-sized enhancing pilot beam on the vehicle.Whole process is controlled with controller, is used for the best, coordination and operation simultaneously.

Particularly, shown in the patent 5092512 and 5454504 of Sturrus application and described overall device and the method for the Guan Liang of rolling, welding and crooked constant cross section, and at a kind of exemplary shearing device shown in the patent 5305625 of Heinz application.If wish to understand the other details of relevant those methods, the reader can consult these disclosures.In addition, their explanation integral body is included in and is used for fully disclosing and illustrating purpose of the present invention herein.Inventive concept can be used with power adjusted variable sweep station, as known in the art those.

Fig. 2 uses the side view of automotive bumpers beams of the present invention when it leaves cut-out equipment 71.

Fig. 3-the 6th passes the cutaway view that Fig. 2 gets.Particularly, these cross sections are similar to and passed the cross section that the similar position (see figure 7) is got in the continuous beam 61 before the steps of bent beam 61.

Fig. 7 is the side view of automotive bumpers beams after roll forming but before buckling.Particularly, the top of beam " partly " section is linearity and constant in cross (compare with the upper part of Fig. 3-6 and also see Fig. 8), and the bottom of beam " partly " section is deformed into the longitudinal shape (contrasting Fig. 3-6) of different three-dimensional changes.It is contemplated that, can join homomorphs not in the beam 72.For example, when beam 61 being bent to when becoming single beam 72, skewed surface 73 (Fig. 2) becomes copline, and aims at surface 74 is installed.Copline is installed the front that surface 74 is suitable for being attached to longitudinal beam, as by set bolt or securing member, and can comprise the pre-punching that is used for fixing bolt and securing member.

Fig. 8 is that the beam of Fig. 7 passes the end-view that exemplary roll forming workshop section moves, and beam 61 is shown simultaneously, and it is kept roller 81 to engage by bottom forming rolls 80 and side.The welding point of finding at workshop section 53 places 82 illustrates at abutting

edge

51 and 52 places.The top of plate " wing limit " (swings) or the progressive forming of side flanges 84 illustrate with position 85-88.It is contemplated that bottom forming rolls 80 and/or side keep roller 81 also can replace with fixing guide block and/or roll whole or in part.Especially, I imagine a kind of modification, have only top roll forming instrument herein, and the bottom combined support of guide block or (non-shaping) roll or guide block and roll.

It is contemplated that, the present invention can be used to make the senior beam that has irregular cross section along their length, simultaneously beam " customization " and optimization various different application be can be used for, as inner transverse bassinet structure beam, frame part, outer lateral be used for to bassinet structure beam, roof bow, windshield framework, rocker/bottom girder, Men Liang, engine mount and instrument panel support.It is contemplated that the inventive concept cost is more competitive, and have than hydroforming more effective/higher production capacity, and provide design flexibility with respect to pressing.

Improve

Show the flow chart (Fig. 9) and the equipment (Fig. 9 A) that are similar to Fig. 1 and 1A respectively, but through revising and be suitable for the drop stamping of the roll forming part front of machine.Say exactly, the sheet material material 32 that can be used for the uncoiling of high strength of materials drop stamping and quenching is heated to temperature (preferably be heated to about 880 °-950 ℃, depend on the chemical composition and the chemical property of material) at least about 850 ℃ in step (100) by heater 101.The duration of heating process can change, and this depends on the BTU ability of heater and depends on whether method stops roll forming or continuity method at the beginning.The length of heater can be extended in case of necessity, so that the speed of coupling machine/method.Heater 101 is located in the punching of plate 32 and the front of forming step 33 at once, near stamping machine 34 and the position of upstream.Mould 35/36 usefulness coolant system 103 cooling, and/or water/cooling agent is applied on the plate of shaping by quench system 103, and the plate that is shaped simultaneously perhaps withdraws from from mould 35/36 as the plate that is shaped still between mould 35/36.The time of cooling is crucial.Cooling must be carried out before material temperature descends unsatisfactoryly.Usually, quenching be during the several seconds of the shaping operation kind or between carry out, be applied on the steel and between mould, compress simultaneously as the mould by cooling and/or cooling agent.

The typical steel that is suitable for hot stamped process is the pre-application formula of Usinor USIBOR 1500.As the material that receives in press 34 and be shaped, preferably yield strength is greater than 370MPa, and preferably tensile strength is greater than 550MPa, and has percentage elongation for greater than 14%.The performance of the USIBOR 1500 of " as receive " is well suited for press forming, because material can draw (that is " stretching " or push the feasible thickness that reduces material).Simultaneously, the back quench behavior of this material is significantly higher; Having yield strength is in the 1000MPa scope, and tensile strength is in the 1500MPa scope, and percentage elongation is in 5% scope.These higher material properties extremely are suitable for energy absorption, have improved the parts crashworthiness, and fabulous intensity and weight ratio is provided.By using this material, can in pressing, in plate, produce darker distortion, and in soleplate, not lose the width (that is in cutting machine 39 before the rip cutting step 38) of as much ..., therefore reduced waste material.In addition, should be noted that unimach work hardening when crooked, therefore limit the once above ability of their bendings.This problem is avoided by hot stamped process, because material can be drawn, and does not have the same problem relevant with the rapid work hardening of sheet material material.By the punching press mild steel material, how more selection scheme is arranged aspect the mobile material in diel, therefore help pressing and can draw/be shaped darker section to become the sheet material material.For example, 30% to 50% darker section can be drawn into the sheet material material.

The uniqueness of inventive concept comprises the ability that the parts that have more competitiveness are produced in the benefit combination of two kinds of very different manufacture methods.Benefit comprises the ability that changes the cross section along the length of parts.Higher strength of parts and the component weight that has reduced be representative when material property increase and cross section are tubulose resulting benefit.Pressing is that cold punching platen press or hot stamped process all have the ability that changes shape across part length.And hot stamped process has as receiving the working ability that mild steel increases, and described mild steel is suitable for being shaped, and makes material change into the material with very high performance then during handling.This transformation realizes after the steel quenching of heating and shaping.Avoided the problem that is associated with work hardening like this, above-mentioned work hardening may take place when the punching press high-strength material ... because having only, the sheet material material when quenching after punching operation, just becomes high strength.In the method, utilize roll forming to receive the plate of process punching press, and finish the shaping of parts.The shaping stage gradually that is associated with roll forming can make the material that is formed with very high strength grade, comprising high strength and unimach.This becomes roll forming to be used for the Perfected process of opening or tubulose pressed form of finally being shaped, and above-mentioned pressed form is hot forming in stamping machine.

Hot stamped process provides the bigger ability with respect to the cold punching platen press, is to carry out with a kind of material rate/intensity because be shaped, and final parts are under more high-grade in addition/intensity.Generally be categorized as mild steel as the material that is used for the hot stamped process reception, and have the performance of the drawing of being well suited for.The steel of heat is shaped in mould and quenching then (perhaps after fast quench) immediately, produces martensitic grain structure like this, and more common material property in the martensite steel, and having tensile strength is greater than 1500MPa.

It should be understood that, under the situation that does not break away from thought of the present invention, can change and revise said structure, and it should also be understood that, these thoughts of the present invention are included by following claim, unless these claims specially have explanation in addition with language.

Claims

1. the equipment of the buttress brace that is suitable for being shaped comprises:

Press, described press comprises some moulds, described mold arrangement becomes by main mobile material on width flat material band to be deformed into the band that is deformed with 3D shape;

Cutting machine, described cutting machine are adjusted to the even width that the band of distortion is cut to desirable constant dimensions; With

Roll former, the linear segment of the even width band that some roll configuration of described roll former become will be out of shape is shaped as continuous beam.

2. equipment as claimed in claim 1, wherein, it is partially-formed with the opposite edges of band that each roll configuration becomes.

3. equipment as claimed in claim 1, wherein, each roll is configured and is arranged to make the opposed edges adjacency of band.

4. equipment as claimed in claim 3 comprises bonding machine, and described bonding machine is configured to described opposed edges is partly welded together beam is configured as permanent continuous pipe.

5. equipment as claimed in claim 4 comprises that one cuts off device, and described shearing device is used for permanent continuous pipe is cut into some beam parts.

6. equipment as claimed in claim 5 comprises a controller, and described controller is used for coordinated mode control press, roll former, bonding machine and shearing device.

7. equipment as claimed in claim 1 comprises crooked workshop section, and described crooked workshop section is configured to make beam to have and vertically goes up crooked shape.

8. equipment as claimed in claim 1, the wherein flat installation surface of mold arrangement shaping.

9. equipment as claimed in claim 8, comprise shearing device, described shearing device is used for continuous beam is cut into some beam parts, wherein roll former comprises crooked workshop section, described crooked workshop section is used for continuous beam is deformed into the shape that vertically goes up bending, and wherein the installation surface is coplanar in each described part.

10. equipment as claimed in claim 1, comprise shearing device, described shearing device is used for continuous beam is cut into some beam parts, and the horizontal cross section that get the end of wherein passing the beam part limits first tubular sections, and the horizontal cross section that get the center of passing the beam part limits second tubular sections, described second tubular sections is different on front/rear direction with first tubular sections, so buttress brace has the geometry in change cross section along some part at least of its length.

11. equipment as claimed in claim 1, wherein, each roll configuration becomes the open section that has different depth along the length shaping of beam.

12. the equipment of the buttress brace that is suitable for being shaped comprises:

Press, described press comprises mould, mold arrangement becomes by mainly being that mobile material is out of shape continuous material band on perpendicular to the direction of the direction of feed that is limited by band length; With

Roll former, the described roll former setting of connecting with press, and have some rolls, described roll configuration and be arranged on direction of feed, receive band, and buttress brace is processed in the marginal portion of the band of distortion.

13. a method may further comprise the steps:

Independent elongated board is provided, and described plate limits a plane, and comprises first, second and the 3rd band part that integral body links together;

By mainly be on perpendicular to the direction on described plane mobile material and punching press first band part so that first band partly be out of shape; With

By using roll former with the second and the 3rd band part roll forming Cheng Liang.

14. method as claimed in claim 13, wherein, punch steps comprises it mainly being to draw material from the width of band rather than from longitudinal direction.

15. method as claimed in claim 13, wherein, the second and the 3rd band part is extended from the relative edge of first band part, and wherein, the roll forming step comprises becoming in abutting connection with contacting with the edge shaping of the 3rd band part second.

16. method as claimed in claim 15, the step that comprises welded edge is with the permanent continuous beam that is shaped.

17. method as claimed in claim 13 comprises continuous beam deflection is become vertical curved step.

18. method as claimed in claim 17, wherein punch steps is included in first band and partly goes up the installation surface that is shaped, and the installation surface configuration becomes to engage and is fixed on the longitudinal beam.

19. step as claimed in claim 13, wherein the roll forming step comprises beam is shaped as to have band different depth sized opening section.

20. a tubulose buttress brace comprises:

Plate of material, described plate is shaped as the Guan Liang with certain-length, and this Guan Liang has interlude, relative construction section and some interludes, and described interlude is connected to the outer end of central segment on the associated end of described construction section;

Pass the first horizontal cross section that central segment is got, the described first horizontal cross section limits around its peripheral first wall length, and this first wall length is first length dimension;

Pass the second horizontal cross section that get the inboard of construction section, the described second horizontal cross section limits the second wall length around its periphery, and the described second wall length is second length dimension;

Pass the 3rd horizontal cross section that the interlude middle part is got, the described the 3rd horizontal cross section limits around its peripheral first wall length, and described the 3rd wall length is the 3rd length dimension;

Second length dimension is different with the first and the 3rd length dimension, and wherein selected first, second and the 3rd length dimension, to optimize local beam strength and with weight and minimal wasteization.

21. beam as claimed in claim 20, wherein first, second has nothing in common with each other with the 3rd length dimension.

22. the method for the buttress brace that is shaped may further comprise the steps:

Press is provided, and described press comprises some shaping dies, and shaping dies is connected with the roll former with some rolls and at the upstream position of this roll former;

The operation mould is with by mainly being to make continuous material band distortion perpendicular to mobile material on by the direction of the direction of feed that band length was limited; With

The roll of operation roll former is processed into buttress brace with the band and the marginal portion of the band of distortion that are received on the direction of feed.

23. the equipment of the buttress brace that is suitable for being shaped comprises:

Press, described press comprises some moulds, mold arrangement one-tenth is deformed into the band that is deformed with 3D shape by the flat band that drawing and mobile material will be heated metal material;

Cooling system, described cooling system is associated with press, and be configured to cooling strain band be heated metal material; With

Roll former, described roll former be in the downstream of press and cooling system, and have some rolls, and described roll configuration becomes the marginal portion of band that will distortion to shape to be continuous beam.

24. equipment as claimed in claim 23 comprises some diels in press, described press has at least a portion cooling system therein.

25. equipment as claimed in claim 24 comprises cutting machine, described cutting machine is set the even width that the band of distortion is cut into desirable constant dimensions for.

26. equipment as claimed in claim 24, wherein mold arrangement becomes on lateral to stretch and extrded material.

27. equipment as claimed in claim 23, wherein cooling system is connected on the mould.

28. equipment as claimed in claim 23, wherein roll configuration and be mounted to the opposed edges part adjacency that makes band.

29. equipment as claimed in claim 28 comprises bonding machine, described bonding machine is configured to opposed edges is partly welded together, so that beam is configured as permanent continuous tubing.

30. equipment as claimed in claim 29 comprises shearing device, described shearing device is used for permanent continuous tubing is cut into some beam parts.

31. equipment as claimed in claim 23 comprises controller, described controller is used for coordinated mode control press, roll former and cooling system.

32. equipment as claimed in claim 23 comprises crooked workshop section, described crooked workshop section makes beam have curved shape in the vertical.

33. equipment as claimed in claim 23, the wherein flat installation surface of mold arrangement shaping.

34. the equipment of the buttress brace that is suitable for being shaped comprises:

Heater, described heater configuration become steel are heated to temperature at least about 850 ℃;

Press, described press comprises some moulds, described mold arrangement becomes to make the continuous band distortion of hot steel;

Cooling system, described cooling system is associated with press, is used for quenching and hardening heat steel; With

The downstream that roll former, described roll former are connected with press and be provided with and be positioned at cooling system, and have some rolls, described roll configuration and be mounted to and on direction of feed, receive described band, and the marginal portion of the band of distortion is processed into buttress brace.

35. a method may further comprise the steps:

Drop stamping has the plate that is heated steel of first tensile strength, comprises drawing and expanded material;

Quenching is through the plate of punching press, so that material has advantages of higher tensile strength; With

By using the part roll forming Cheng Liang of roll former with the plate that is stamped.

36. method as claimed in claim 35 wherein is to carry out along the marginal portion of plate in the outside of the core of plate as the step 1 of roll forming.

37. method as claimed in claim 35, wherein the yield strength that has after quenching of material is at least about 1000MPa.

38. method as claimed in claim 35, wherein the tensile strength that has after quenching of material is at least about 1500MPa.

39. method as claimed in claim 35 comprises the edges abut of plate and welds together then, so that be shaped permanent tubing.

40. method as claimed in claim 35 comprises that beam deflection with continuous becomes the step of vertical curve shape.

41. method as claimed in claim 40, wherein punch steps is included in first band and partly goes up the installation surface that is shaped, and described installation surface configuration becomes to engage and is fixed on the longitudinal beam.

42. the method for the buttress brace that is shaped may further comprise the steps:

Heater is provided;

The cooling system that provides press to be associated with press in addition, described press comprises some shaping dies; Above-mentioned shaping dies is at the downstream position of heater;

Roll former with some rolls is provided, and described roll former is connected with press and in the downstream of press;

The heating material band;

The operation mould is to make the distortion of material band by drawing the also after this quick coolant of hot material; And

The roll of operation roll former to be receiving band on direction of feed, and buttress brace is processed in the marginal portion of the band of distortion.