Roller tool for a machine tool, roller tool system, and method for the linear forming of a metal sheet

Abstract

A roller tool for a machine tool for the linear forming of a metal sheet comprises a housing, a tool head which for reversibly interacting with a ram of the machine tool is mounted so as to be rotatable relative to the housing about a tool longitudinal axis, having an impact face for transmitting a contact pressure force that is oriented so as to be parallel to the tool longitudinal axis from the ram to the tool head, and a rotary engagement for transmitting a rotating movement about the tool longitudinal axis from the ram to the tool head, and a roller installation for interacting with the metal sheet, having at least one roller body that is capable of being rotatingly driven by way of the tool head.

Claims

1. A roller tool for a machine tool for the linear forming of a metal sheet, comprising a housing; a tool head for reversibly interacting with a ram of the machine tool which is mounted so as to be rotatable relative to the housing about a tool longitudinal axis, with an impact face for transmitting a contact pressure force that is oriented so as to be parallel to the tool longitudinal axis from the ram to the tool head; and a rotary engagement for transmitting a rotating movement about the tool longitudinal axis from the ram to the tool head; and a roller installation for interacting with the metal sheet, with at least one roller body that is capable of being rotatably driven by way of the tool head; and a safety clutch for limiting a maximum torque transmittable between the tool head and the roller body; wherein the rotary engagement is configured as a form-fit profile for transmitting the rotating movement in a form-fitting manner from the ram to the roller tool.

2. The roller tool according to claim 1, comprising at least one of the group comprising a bevel gear mechanism and a worm gear mechanism for transmitting the rotating movement between the tool head and the roller body.

3. The roller tool according to claim 1, comprising a spur gear mechanism for transmitting the rotating movement between the tool head and the roller body.

4. The roller tool according to claim 1, comprising at least two shafts which for transmitting the rotating movement between the tool head and the roller body are oriented so as to be perpendicular to the tool longitudinal axis and are disposed so as to be mutually spaced apart along the tool longitudinal axis.

5. The roller tool according to claim 1, wherein a driving part of the safety clutch is connected directly to the tool head.

6. The roller tool according to claim 1, wherein the roller installation has a secondary roller body which for interacting with the metal sheet is mounted on a roller shaft that transmits the rotating movement so as to be rotatable relative to the roller body.

7. The roller tool according to claim 6, comprising a lubricant duct which for feeding lubricant to the secondary roller body is incorporated in the roller shaft.

8. A roller tool system, comprising the roller tool according to claim 1; and a counter roller tool, with a counter housing; and at least one counter roller which for interacting with a metal sheet is mounted so as to be rotatable in the counter housing.

9. A method for the linear forming of a metal sheet, comprising the following steps: providing a roller tool for a machine tool, comprising a tool head and a roller installation with at least one roller body; providing the metal sheet; pressing the roller body onto the metal sheet by exerting a contact pressure force from a ram of the machine tool onto the tool head; rotatingly driving the roller body that interacts with the metal sheet by transmitting a rotating movement in a form-fitting manner from the ram to a rotary engagement of the tool head that is configured as a form-fit profile; repositioning the metal sheet relative to the roller tool for forming the metal sheet in a linear manner; wherein a maximum torque transmittable between the tool head and the roller body is limited by means of a safety clutch.

10. The method according to claim 9, wherein the rotating driving of the roller body is performed in such a way that it is coupled to the repositioning of the metal sheet relative to the roller tool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a lateral view of a schematically illustrated machine tool having a roller tool system.

(2) FIG. 2 shows a perspective illustration of the roller tool system in FIG. 1, seen from obliquely below, having a roller tool and a counter roller tool, wherein the roller tool has a roller installation having a roller body which for interacting with a metal sheet is capable of being rotatingly driven.

(3) FIG. 3 shows a perspective illustration of the roller tool systems in FIG. 1, seen from obliquely above, wherein the roller tool has a tool head having a rotary engagement for transmitting a rotating movement from a ram of the machine tool to the tool head.

(4) FIG. 4 shows a sectional illustration of the roller tool system along the section line IV-IV in FIG. 2, through a tool longitudinal axis, wherein the metal sheet for the linear forming is disposed between the roller tool and the counter roller tool.

(5) FIG. 5 shows a sectional illustration of the roller tool system along the section line V-V in FIG. 4, parallel to and spaced apart from the tool longitudinal axis, wherein a safety clutch of the roller tool is illustrated in a non-sectional manner.

(6) FIG. 6 shows a sectional illustration of the roller tool system along the section line VI-VI in FIG. 4, having the metal sheet formed in a linear manner along a forming path.

DETAILED DESCRIPTION

(7) A machine tool 1 as is illustrated in FIG. 1 comprises a frame structure 2, a machine turret 3, connected to said frame structure 2, for receiving machining tools 4, a machining table 5 for supporting a metal sheet 6 to be machined, and a positioning installation 7 for repositioning the metal sheet 6 relative to the machining table 5.

(8) The positioning installation 7 comprises a positioning drive 8 which is operatively connected to a metal-sheet clamping means 9. The metal sheet 6 is reversibly fastened to the metal-sheet clamping means 9 and by means of the positioning drive 8 is repositionable relative to the machining table 5.

(9) An activation means 11 having a ram 12 is disposed on a frame upper part 10 of the frame structure 2. The activation means 11 by way of the ram 12 interacts with the respective machining tool 4 that is disposed thereunder. To this end, the ram 12 for exerting a contact pressure force F on the machining tool 4 is repositionable in the vertical direction, and for transmitting a rotating movement to the machining tool 4 is capable of being rotatingly driven about a vertical axis.

(10) The machine turret 3 is mounted so as to be capable of being rotatingly driven on the frame structure 2. Various machining tools 4 are capable of being disposed below the activation means 11 by rotatingly driving the machine turret 3.

(11) The machining tool 4 that is disposed below the activation means 11 is configured as a roller tool system 13. The roller tool system 13 comprises a roller tool 14 and a counter roller tool 15. The metal sheet 6 is disposed between the roller tool 14 and the counter roller tool 15.

(12) The roller tool system 13 is illustrated in more detail in FIG. 2. The roller tool 14 has a housing 16, a tool head 18 which is mounted so as to be rotatable relative to the housing 16 about a tool longitudinal axis 17, and a roller installation 19 which for interacting with the metal sheet 6 is connected to the housing 16.

(13) As is derived in particular from FIG. 3, the tool head 18 for reversibly interacting with the ram 12 comprises an impact face 20 and a rotary engagement 21. The impact face 20 is configured such that the contact pressure force F that is oriented so as to be parallel to the tool longitudinal axis 17 by way of said impact face 20 is transmittable from the ram 12 to the tool head 18. The rotating movement about the tool longitudinal axis 17 by way of the rotary engagement 21 is transmittable from the ram 12 to the tool head 18. The rotary engagement 21 for interacting in a form-fitting manner with the ram 12 about the tool longitudinal axis 17 is configured as a groove that extends radially in relation to the tool longitudinal axis 17. In order for the rotary engagement 21 to be configured, the tool head 18 thus has a keyhole-shaped depression.

(14) A longitudinal section of the roller tool system 13 through the tool longitudinal axis 17 is illustrated in FIG. 4. The tool head 18 by way of a head bearing 22 on a housing upper part 23 of the housing 16 is mounted so as to be rotatable about the tool longitudinal axis 17. The head bearing 22 is configured as a ball bearing. The housing upper part 23 by means of a housing screw fitting 24 is connected in a force-fitting manner to a housing lower part. The housing lower part 25 has a housing flange 26 for connecting to the machine turret 3. The housing 16 by means of an indexing drive (not illustrated) of the machine tool 1, in particular by way of the housing upper part 23, is capable of being rotatingly driven about the tool longitudinal axis 17 relative to the machine turret 3.

(15) The tool head 18 is connected in a rotationally fixed manner to a safety clutch 27. The safety clutch 27 has a driving part 28 and an output part 29. The driving part 28 by way of a head-to-clutch connection 30 is connected in a rotationally fixed manner to the tool head 18. The head-to-clutch connection 30 comprises a feather key connection. The safety clutch 27 is capable of being disposed in a closed position and in an opened position. The output part 29 in the closed position is connected in a rotationally fixed manner to the driving part 28. The output part 29 in the opened position is rotatable about the tool longitudinal axis 17 relative to the driving part 28. The safety clutch 27 is configured in such a manner that said safety clutch 27 is repositionable between the closed position and the opened position, depending on the torque bearing on the driving part 28. The safety clutch 27 is repositioned in a self-acting manner from the closed position to the opened position when a maximum transmittable torque is exceeded.

(16) The safety clutch 27, in particular the output part 29, by way of a clutch-to-gear connection 31 is connected in a rotation-transmitting manner to a gear installation 32. The clutch-to-gear connection 31 comprises a feather key connection for transmitting the rotating movement in a form-fitting manner from the safety clutch 27 to the gear installation 32. Said gear installation 32 has two sprocket shafts 33, 34 which are mounted so as to be rotatable on the housing 16, in particular on the housing lower part 25. A rotation axis of the respective sprocket shaft 33, 34 is oriented so as to be perpendicular to the tool longitudinal axis 17. The sprocket shafts 33, 34 by way of friction bearing bushes 35 are mounted so as to be rotatable on the housing lower part 25. The sprocket shafts 33, 34 in the axial direction are fastened to the housing lower part 25 by means of securing rings 36.

(17) The output part 29 for rotatingly driving the upper sprocket shaft 33 is connected to the upper sprocket shaft 33 so as to be capable of being rotatingly driven by way of a bevel gear mechanism 37. A diameter D.sub.KK of a clutch bevel gear 38 disposed on the safety clutch 27 is 15% smaller than a diameter D.sub.RK of a sprocket bevel gear 39 that is disposed on the upper sprocket shaft 33. The sprocket bevel gear 39 by way of a feather key connection is connected in a form-fitting manner to the upper sprocket shaft 33.

(18) The upper sprocket shaft 33 for transmitting the rotating movement from the upper sprocket shaft 33 to the lower sprocket shaft 34 has an upper spur gear 40 that is connected to said upper sprocket shaft 33 in a rotationally fixed manner, and the lower sprocket shaft 34 has a lower spur gear 41 that is connected to said lower sprocket shaft 34 in a rotationally fixed manner. A diameter Dos of the upper spur gear 40 is equal to a lower diameter D.sub.US of the lower spur gear 41. The lower sprocket shaft 34 in the region of the sprocket bevel gear 39 has a bevel gear notch 42. In a lateral view in the direction of the rotation axis of the lower sprocket shaft 34, the lower sprocket shaft 34 and the sprocket bevel gear 39 mutually overlap.

(19) The gear installation 32 comprises a roller shaft 43 which is mounted so as to be rotatable on the housing 16, in particular on the housing lower part 25. The roller shaft 43 is axially established on the housing lower part 25 by means of securing rings 36. The roller shaft 43 by way of a roller sprocket 44 that is connected in a rotationally fixed manner to said roller shaft 43 and by way of the lower spur gear 41 is connected to the lower sprocket shaft 34 so as to be capable of being rotatingly driven.

(20) The roller installation 19 for interacting with the metal sheet 6 comprises a roller body 45. The roller body 45 by way of a feather key connection is connected in a rotationally fixed manner to the roller shaft 43. The roller body 45 by way of the gear installation 32 and the safety clutch 27 is connected to the tool head 18 so as to be capable of being rotatably driven. The roller body 45 for interacting with the metal sheet 6 has a hardened metallic surface.

(21) The roller installation 19 has a roller sleeve 46 and a secondary roller body 47. The roller sleeve 46 and the secondary roller body 47 are rotatably mounted on the roller shaft 43. The secondary roller body 47 for interacting with the metal sheet 6 has a surface from a hardened metallic material.

(22) The tool head 18 for feeding cooling lubricant from the ram 12 to the roller tool 14 has a head bore 48. The roller shaft 43 comprises a lubricant duct 49. The lubricant duct 49 comprises a central bore 50 that is disposed so as to be concentric with the roller shaft 43, and branch ducts 51 which extend radially between the central bore 50 and the housing lower part 25, the roller sleeve 46, and the secondary roller body 47. A lubricating nipple 52 for introducing lubricant into the lubricant duct 49 is disposed on the central bore 50.

(23) The counter roller tool 15 comprises a counter roller axle 53. The counter roller axle 53 is attached so as to be rotationally fixed on a counter housing 54. A forming roller 55 and two counter roller bodies 56, 57 are rotatably mounted on the counter roller axle 53, said counter roller bodies 56, 57 being disposed so as to neighbour said forming roller 55. The forming roller 55 and the two counter roller bodies 56, 57 are configured for interacting with the metal sheet 6. To this end, the forming roller 55 and the counter roller bodies 56, 57 have a hardened metallic surface.

(24) The counter roller axle 53 comprises a counter lubricant duct 58 which is connected to the forming roller 55 and the counter roller bodies 56, 57. Lubricant can be introduced into the counter lubricant duct 58 by way of a lubricating nipple 52.

(25) The counter housing 54 is mounted on the machine tool 1 so as to be rotatable relative to the machine turret 3. The counter housing 54 by way of a drive engagement 59 is capable of being rotatably driven by means of the indexing drive.

(26) The functional mode of the roller tool system 13 having the roller tool 14 and the counter roller tool 15 is as follows:

(27) The roller tool system 13 is initially disposed in a resetting position. The roller tool system 13 in the resetting position is disposed below the activation means 11, wherein the tool head 18 is disposed below the ram 12. The metal sheet 6 is disposed between the roller tool 14 and the counter roller tool 15. The roller tool 14 is disposed so as to be spaced apart, in particular in the vertical direction, from the metal sheet 6.

(28) The metal sheet 6 by activating the positioning installation 7 is repositioned relative to the roller tool system 13. A region of the metal sheet 6 to be machined is disposed in the vertical direction above the forming roller 55. The roller tool 14 for the linear forming of the metal sheet 6 is repositioned in the vertical downward direction by means of the ram 12. To this end, the ram 12 interacts with the impact face 20 of the tool head 18. The contact pressure force F is transmitted from the ram 12 to the metal sheet 6 by way of the tool head 18, the housing 16, the roller shaft 43, as well as the roller body 45 and the secondary roller body 47. The roller tool 14 is situated in the operating position.

(29) The metal sheet 6 is guided between the roller body 45 and the first counter roller body 56, as well as between the secondary roller body 47 and the second counter roller body 57. The metal sheet 6 is formed by means of the forming roller 55.

(30) The metal sheet 6 for the linear forming thereof is repositionable relative to the roller tool system 13 by means of the positioning installation 7. The metal sheet 6 is repositioned relative to the roller tool system 14 in a manner substantially perpendicular to the tool longitudinal axis 17 and to the rotation axis of the roller shaft 43. To this end, the metal-sheet clamping means 9 can be repositioned relative to the roller tool system 13 in an arbitrary direction, in particular in the direction of the roller tool system 13.

(31) The metal sheet 6, by repositioning the metal sheet 6 along a forming path 60 relative to the roller tool system 13 disposed in the operating position is formed, in particular in a corrugated manner. The roller body 45, the secondary roller body 47, the first counter roller body 56, the second counter roller body 57, and the forming roller 55 hereby role on the metal sheet 6. The forming path 60 is configured so as to be curved. The metal sheet 6 is formed along a curved line by rotating the roller tool system 13 by means of the indexing drive, in particular while repositioning the metal sheet 6 relative to the roller tool system 13.

(32) The rotating movement is transferred from the ram 12 to the tool head 18 by way of the rotary engagement 21. The rotating movement is transmitted from the tool head 18 by way of the safety clutch 27 and the gear installation 32 to the roller body 45. The rotating movement of the roller body 45 is adapted to the repositioning of the metal sheet 6 relative to the roller tool system 13. In particular, the rotating movement of the roller body 45 is adapted to the rotating movement of the roller tool system 13 relative to the metal sheet 6. To this end, the indexing drive, the activation means 11, and the positioning installation 7 are connected in terms of signalling to a control installation of the machine tool 1.

(33) The roller body 45 in a curved region of the forming path 60 is driven in such a manner that a circumferential rolling speed of the roller body 45 is higher or lower than a relative speed of the roller tool system 13, relative to the metal sheet 6, in the region of the tool longitudinal axis 17. The circumferential rolling speed on straight portions of the forming path 60 corresponds to the relative speed between the metal sheet 6 and the roller tool system 13. On account thereof, particularly thick metal sheets 6, in particular having a metal-sheet wall thickness t of more than 2.5 mm, can be reliably formed. Thin metal sheets 6 having a metal-sheet wall thickness t of at most 0.5 mm can be reliably formed without creasing.

(34) Cooling lubricant is fed to the roller tool system 13 during the forming process by way of the head bore 48. For minimizing friction and wear, lubricant by way of the lubricant duct 49 and the counter lubricant duct 58 is delivered between the roller shaft 43 and the roller sleeve 46, the secondary roller body 47 and the housing lower part 25, as well as between the counter roller axle 53 and the counter roller bodies 56, 57 and the forming roller 55.

(35) The safety clutch 27 is repositioned from the closed position to the opened position when a maximum torque transmittable between the tool head 18 and the roller body 45, in particular between the driving part 28 and the output part 29 is exceeded. The driving part 28 in the opened position is rotatable relative to the output part 29, wherein the transmission of the rotating movement between the tool head 18 and the roller body 45 is interrupted.

(36) The roller tool system 13 having the roller body 45 that by way of the tool head 18 is capable of being rotatingly driven is dimensioned in a compact manner, is robust when in operation, and can be used in a particularly flexible manner. The roller tool system 13 enables the linear forming of the metal sheet 6 along the straight and/or curved forming path 60 in a flexible and reliable manner, wherein metal sheets 6 having a particularly small metal-sheet wall thickness t of at most 0.5 mm, as well as metal sheets 6 having a particularly large metal-sheet wall thickness t of at least 2.5 mm can be formed in particular. The roller tool system 13 for forming the metal sheet 6 herein can be repositioned relative to the metal-sheet clamping means 9 in an arbitrary direction, in particular in the direction of the metal-sheet clamping means 9, without bulging or creasing of the metal sheet 6 arising.