A multi-axis roll-forming system for forming a stepped diameter in a cylinder includes a support that spins about a rotation axis while supporting a workpiece that includes the cylinder. A first actuator translates a first roller perpendicularly to the rotation axis. A second actuator moves a multi-axis roller radially outward, relative to the rotation axis, and upward along the rotation axis. The system may also include a first roller arm to which the multi-axis roller is coupled. The first roller arm is connected to a pivot joint having a pivot axis that is perpendicular to the rotation axis. The second actuator may include a linear-drive actuator that is coupled to the first roller arm and extends along the rotation axis to force the multi-axis roller to pivot about the pivot axis.

A multi-axis roll-forming system for forming a stepped diameter in a cylinder. The system includes a support configured to spin about a rotation axis while supporting a workpiece including a cylinder. A first actuator is configured to translate a first roller perpendicular to rotation axis. The first roller includes a truncated conical work surface configured to press against the inward-facing surface of the cylinder to angle it outward according to a slant angle of the truncated conical work surface.

A multi-axis roll-forming method includes simultaneously (a) spinning, about a rotation axis, a spin platter having placed thereon a ring encircling the rotation axis, (b) pressing at least one first roller against outward-facing surface of a first portion of the ring to press the first portion against an outward-facing surface of the spin platter, and (c) forcing a second roller against an outward-facing surface of a second portion of the ring to bend toward the rotation axis the second portion, so as to form a lip extending toward the rotation axis, wherein the step of forcing includes (i) pivoting the second roller against the second portion, and (ii) translating the second roller along the second portion toward the rotation axis.

A multi-axis roll-forming method includes simultaneously (a) spinning, about a rotation axis, a spin platter having placed thereon a ring encircling the rotation axis, (b) pressing at least one first roller against outward-facing surface of a first portion of the ring to press the first portion against an outward-facing surface of the spin platter, and (c) forcing a second roller against an outward-facing surface of a second portion of the ring to bend toward the rotation axis the second portion, so as to form a lip extending toward the rotation axis, wherein the step of forcing includes (i) pivoting the second roller against the second portion, and (ii) translating the second roller along the second portion toward the rotation axis.

The present invention relates to methods of working sheet metal, and sheet metal working apparatus for performing such methods. Such methods include steps of providing a sheet metal workpiece having first and second surfaces opposed to each other and at least one edge, bending the workpiece to form at least a first sidewall portion defined between the edge and a basal region, the first sidewall portion thereby defining a curved fold region in the sheet metal workpiece adjacent the first sidewall portion. Following this, first anvil tool and a first forming tool are provided for contact with and constraint of the first and second surfaces of the sheet metal workpiece respectively. The forming tool and/or the anvil tool are then progressively slid along the curved fold region to cause shear material transfer in the curved fold region to further deform the curved fold region. Such methods can allow for formation of components of similar shape as made at present by deep drawing methods, but with less wastage of the starting material.

To a fulcrum roll unit portion in a workpiece, a corresponding initial curvature radius is applied, and to a bending roll unit portion in a workpiece, a corresponding design curvature radius is applied. To an intermediate unit portion in a workpiece, an intermediate curvature radius set so as to continuously change from the initial curvature radius to the design curvature radius is applied. At least one of the fulcrum roll and the bending roll is moved on the basis of an integrated value obtained by integrating the amount of change in bending position in each of the intermediate unit portion and the bending roll unit portion.

To a fulcrum roll unit portion in a workpiece, a corresponding initial curvature radius is applied, and to a bending roll unit portion in a workpiece, a corresponding design curvature radius is applied. To an intermediate unit portion in a workpiece, an intermediate curvature radius set so as to continuously change from the initial curvature radius to the design curvature radius is applied. At least one of the fulcrum roll and the bending roll is moved on the basis of an integrated value obtained by integrating the amount of change in bending position in each of the intermediate unit portion and the bending roll unit portion.

The invention relates to a method for continuously roller-forming and hardening sheet steel in which a sheet steel strip is continuously roller-formed into a profile in a roller-profiling unit, characterized in that the roller-formed profile strand is preheated to a temperature below the austenite starting temperature (Ac.sub.1) and the roller-formed profile strand is then heated across subregions of its cross-section and/or subregions of its length to a temperature above AC.sub.3, with the roller-formed profile strand being acted on with tension at least during the heating of subregions to a temperature >AC.sub.3.

The invention relates to a method for continuously roller-forming and hardening sheet steel in which a sheet steel strip is continuously roller-formed into a profile in a roller-profiling unit, characterized in that the roller-formed profile strand is preheated to a temperature below the austenite starting temperature (Ac.sub.1) and the roller-formed profile strand is then heated across subregions of its cross-section and/or subregions of its length to a temperature above AC.sub.3, with the roller-formed profile strand being acted on with tension at least during the heating of subregions to a temperature >AC.sub.3.

To a fulcrum roll unit portion in a workpiece, a corresponding initial curvature radius is applied, and to a bending roll unit portion in a workpiece, a corresponding design curvature radius is applied. To an intermediate unit portion in a workpiece, an intermediate curvature radius set so as to continuously change from the initial curvature radius to the design curvature radius is applied. At least one of the fulcrum roll and the bending roll is moved on the basis of an integrated value obtained by integrating the amount of change in bending position in each of the intermediate unit portion and the bending roll unit portion.