Method and device for shearing rod material
11040405 · 2021-06-22
Assignee
Inventors
Cpc classification
B23D33/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A method is disclosed for shearing an end section from a rod material by means of a cutting blade that is movable against a stationary blade, transversely with respect to the longitudinal direction of the rod material, during the shearing operation. The end section to be sheared is brought into contact on its end-face side with a longitudinal stop and is acted on, via the longitudinal stop, with a pressure force in the longitudinal direction of the rod material. The action of pressure force on the end section takes place during the shearing operation with a position-controlled longitudinal position of the longitudinal stop. It is thus possible to manage with a lower pressure force than with conventional force-controlled pressure force action, without the shearing quality of the separation faces at the end section being impaired.
Claims
1. A method for shearing an end section from a rod material by means of a cutting blade that is movable against a stationary blade, transversely with respect to a longitudinal direction of the rod material comprising: bringing the end section to be sheared into contact on an end-face side with a longitudinal stop, and during the shearing operation acting on the end section, via the longitudinal stop, with a pressure force in the longitudinal direction of the rod material, wherein the action of pressure force on the end section during the shearing operation takes place with a position-controlled longitudinal position of the longitudinal stop, wherein a position measuring apparatus, controller and hydraulic system together allow the end section to be acted on by the pressure force with the position-controlled longitudinal position of the longitudinal stop, and wherein the longitudinal position of the longitudinal stop is controlled to a constant value during the shearing operation.
2. The method according to claim 1, wherein a course of the pressure force exerted by the longitudinal stop on the end section during the shearing operation is measured.
3. The method according to claim 2, wherein in the event of inadequate quality of the shear surface of the end section, a change is made to an operating mode in which the action of pressure force on the end section to be sheared takes place in a force-controlled manner, wherein the pressure force exerted by the longitudinal stop on the end section to be sheared is controlled according to a predefined force control variable.
4. The method according to claim 2, wherein the course of the measured pressure force is evaluated in order to assess the quality of a shear surface of the end section.
5. The method according to claim 4, wherein in the event of inadequate quality of the shear surface of the end section, a change is made to an operating mode in which the action of pressure force on the end section to be sheared takes place in a force-controlled manner, wherein the pressure force exerted by the longitudinal stop on the end section to be sheared is controlled according to a predefined force control variable.
6. The method according to claim 4, wherein in the event of inadequate quality of the shear surface of the end section, a change is made to an operating mode in which the action of pressure force on the end section to be sheared takes place in a force-controlled manner, wherein the pressure force exerted by the longitudinal stop on the end section to be sheared is controlled according to a predefined force control variable.
7. The method according to claim 6, wherein the quality of the shear surface is assessed as inadequate when the course of the measured pressure force has a dip prior to the end of the shearing operation, in which the course of the pressure force, disregarding control-related fluctuations, drops to a minimum and then rises again.
8. The method according to claim 4, wherein the quality of the shear surface is assessed as inadequate when the course of the measured pressure force has a dip prior to the end of the shearing operation, in which the course of the pressure force, disregarding control-related fluctuations, drops to a minimum and then rises again.
9. The method according to claim 8, wherein the quality of the shear surface is assessed as inadequate when the course of the measured pressure force rises from the minimum by a difference that is at least 10% of the maximum value of the measured pressure force.
10. The method according to claim 9, wherein the difference is 15% to 30% of the maximum value of the measured pressure force.
11. The method according to claim 8, wherein the quality of the shear surface is assessed as inadequate when the course of the measured pressure force prior to an end of the shearing operation drops to a value that is less than or equal to zero.
12. The method according to claim 1, wherein in the event of inadequate quality of a shear surface of the end section, a change is made to an operating mode in which the action of pressure force on the end section to be sheared takes place in a force-controlled manner, wherein the pressure force exerted by the longitudinal stop on the end section to be sheared is controlled according to a predefined force control variable.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The method according to the invention and the device according to the invention are described in greater detail below with reference to the appended drawings, based on exemplary embodiments. The drawings show the following:
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DESCRIPTION OF THE INVENTION
(8) The following applies for the description below: If reference numerals are indicated in a figure for the purpose of clarity of the illustrations, but are not mentioned in the directly associated portion of the description, reference is made to their explanation in the preceding or subsequent portions of the description. Conversely, to avoid excessive detail in the illustrations, reference numerals that are less relevant for direct understanding are not provided in all figures. In this regard, reference is made to the respective other figures.
(9) The device illustrated in
(10) The stationary blade 10 and the movable cutting blade 30 are slightly offset in the longitudinal direction, and between them define a shear plane S. The shear plane S is normally perpendicular to the longitudinal direction A of the rod material R. The piece of the rod material R that protrudes beyond the stationary blade 10 and the shear plane S until reaching the longitudinal stop 50 forms an end section R.sub.E, which is sheared off from the remainder of the rod material R by the device.
(11) The movable cutting blade 30 is driven by a drive means, known per se, which is symbolized in the drawing by an arrow 35. The shearing movement runs in the direction toward the stationary blade 10. The actual shear path thereby covered is defined as the route of the cutting blade 30 between its engagement with the rod material R and the complete shearing of the end section R.sub.E from the rod material R, and thus corresponds essentially to the transverse dimension of the rod material R in the direction of movement of the cutting blade 30.
(12) For inserting or feeding the rod material R, feed means, known per se, symbolized in the drawing only by an arrow 1 are provided which include, for example, an openable and closable retraction apparatus which engages at the circumference of the rod material R, and which is movably drivable back and forth in the longitudinal direction.
(13) The rod material R may be held in the longitudinal direction during the shearing operation by means of the clamping device 20. For this purpose, the clamping device 20 is pressable against the rod material R. The drive means, known per se, required for this purpose are symbolized in the drawing by an arrow 25.
(14) As further shown in
(15) The stop shank 52 is screwed to a coaxial piston rod 61 and is thus kinematically coupled in the longitudinal direction. The piston rod 61 is in turn kinematically connected to a stop piston 62, in particular in a one-piece design with same. The stop piston 62 and its piston rod 61 are axially movably supported in a piston chamber 63 of a stationary piston housing 60. Connecting lines 65 and 66 for a hydraulic medium open into the piston chamber 63, in the axial or longitudinal direction in front of and behind the piston 62. The stop piston 62, and thus indirectly also the longitudinal stop 50, may be acted on with pressure in the direction toward the end section R.sub.E of the rod material R via the connecting line 65. The pressure force generated by this action of pressure is denoted by reference sign F.sub.D in
(16) The piston rod 61 and the stop piston 62 have an axial borehole 64 into which a rod-shaped position measuring probe 71 of a position measuring apparatus 70 extends. The position measuring probe 71 is stationary. Situated in the stop piston 62 is a position magnet 72 which annularly surrounds the position measuring probe 71 and which is movable together with the stop piston 62. The position measuring apparatus 70 operates according to the magnetostrictive principle. A ferromagnetic measuring element (waveguide) is situated within the position measuring probe 71, and is thus protected. The moved position magnet 72 generates a longitudinal magnetic field in the waveguide. When a current pulse runs through the position measuring probe 71, a second magnetic field results which extends radially around the longitudinal magnetic field. The meeting of both magnetic fields at the measuring point induces angular momentum in the waveguide. This angular momentum runs as a torsional structure-borne sound wave at ultrasonic speed from the measuring point to a sensor electronics system 73 at the head of the position measuring probe 71. The sensor electronics system 73 detects the structure-borne sound wave with high accuracy, and converts it into displacement-proportional position signals, on the basis of which the axial position of the stop piston 62 and thus also the axial position of the longitudinal stop 50 are detectable. The position measuring apparatus 70 preferably has a very high resolution in the range of 1 μm.
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(18) The hydraulic system includes a hydraulic pressure supply 81, a hydraulic pressure store 82, a hydraulic tank 83, and a continuously controllable servo valve 84. The servo valve 84 is controlled by a controller 90 that cooperates with the position measuring apparatus 70. The hydraulic pressure store 82 is in communicating connection with the connecting lines 65 and 66 in the piston housing 60 via the servo valve 84 (depending on the position thereof). The hydraulic tank 83 is connected to the servo valve 84. The corresponding lines conducting hydraulic medium are denoted by reference numerals 86, 87, 88, and 89. In practice, as is apparent from
(19) The basic operating principle of the hydraulic system is as follows:
(20) As the result of the servo valve 84 opening due to control by the controller 90, pressurized hydraulic medium flows from the hydraulic pressure store 82, via the line 88, into the piston housing 60 and acts on the stop piston 62, thus moving it. The line 89 is connected to the line 87, so that the displaced hydraulic medium is able to flow into the hydraulic tank 82. The controlled pressure buildup in the piston housing takes place by appropriate control of the servo valve 84 via the controller 90, in timing with the movement of the cutting blade 30. To reduce the pressure, the servo valve 84 is adjusted in such a way that the line 88 is connected to the line 87, and the hydraulic medium is able to flow into the hydraulic tank 82.
(21) To reset the stop piston 62, the servo valve 84 is set in such a way that hydraulic medium is able to flow from the hydraulic pressure store 82, via the line 89, into the piston housing 60 and act on the piston from the other side. The line 88 is connected to the line 87, so that the displaced hydraulic medium is able to flow into the hydraulic tank 82. Alternatively, an appropriately situated spring assembly or the like may be provided for resetting the stop piston 62. It is also possible for the stop piston 62 to be reset by the feed movement of the rod material R.
(22) The basic operating principle of the method according to the invention is as follows:
(23) At the beginning of a method cycle, the rod material R is moved in the longitudinal direction A between the stationary blade 10 and the movable cutting blade 30, shown in the starting position in
(24) In the next method step, the rod material R is pressed against the stationary blade 10 by means of the clamping device 20, and is thus secured against displacement in the longitudinal direction (
(25) The shearing operation subsequently begins. For this purpose, the movable cutting blade 30 is moved transversely with respect to the longitudinal direction of the rod material R in the direction of the stationary blade 10. As soon as the movable cutting blade 30 comes into engagement with the rod material R, the rod material is pressed against the stationary blade 10, so that the stationary blade 10 with its shear lip 12a also comes into engagement with the rod material R.
(26) Immediately thereafter or with a slight delay, the longitudinal stop 50 is pressed against the end section R.sub.E of the rod material R via the stop piston 62, so that the end section R.sub.E is acted on by a pressure force F.sub.D in the longitudinal direction of the end section. At this point in time, the shear lip 12a of the stationary blade 10 is already engaged with the rod material R and supports same, so that the rod material is not able to move back under the pressure force F.sub.D. This support in the longitudinal direction, is still assisted by the clamping device 20, if present.
(27) The pressure force F.sub.D acting on the end section R.sub.E of the rod material R generates a state of compressive stress in the end section R.sub.E which is superimposed on the shear stresses and tensile stresses, and prevents crack formation and other undesirable artifacts.
(28) The movable cutting blade 30 is now moved further transversely with respect to the rod material R, with application of pressure force F.sub.D, until the end section R.sub.E is completely sheared off. The action of the pressure force F.sub.D on the end section R.sub.E is terminated just before, or at the latest at the end of, the shear path (when the end section R.sub.E is completely sheared off).
(29) The sheared-off end section R.sub.E is now removed, and the movable cutting blade 30 and the longitudinal stop 50, and optionally the clamping device 20, are moved back to their respective starting positions. A new method cycle may now begin.
(30) With the exception of the specific design of the hydraulic system and of the position measuring apparatus 70, the device according to the invention and the method according to the invention correspond to the known prior art, as described in detail in particular in CH 702 984 B1, discussed at the outset. Therefore, those skilled in the art require no further detailed discussion.
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(32) During shearing of rod material, the force acting axially on the longitudinal stop 50 is approximately one-fourth of the shear force. The shear force is higher the greater the diameter of the rod to be sheared, or the lower the heating temperature. This results in relatively large forces that may bring about a certain deflection of the longitudinal stop after the play in the drive of the longitudinal stop itself has been eliminated. This deflection, which takes place in the tenths of a millimeter range, has a significant influence on the state of stress in the shear zone, and thus, on the deformability and the fracture behavior of the material.
(33) To achieve the desired shearing quality of the separation faces on the section, the proportion of the fracture face or the breakout on the entire shear surface must be kept as small as possible by processing engineering and technical measures for the shearing process or the shearing device. As described in greater detail below, this takes place via an active contribution to the state of stress in the end section by means of the longitudinal stop 50.
(34) According to one of the most important aspects of the invention, this active contribution to the state of stress takes place via an action of pressure force on the end section R.sub.E with a position-controlled longitudinal position of the longitudinal stop 50. This is understood to mean that the (axial) longitudinal position of the longitudinal stop 50 during the shearing operation is controlled to a constant value as soon as the longitudinal stop 50 is in contact with the end section R.sub.E. The mentioned deflection of the longitudinal stop 50 is counteracted by the control of the position of the longitudinal stop 50, in that the hydraulic pressure acting on the longitudinal stop 50 via the stop piston 62, and thus, the force F.sub.D acting on the end section R.sub.E, is appropriately controlled. This takes place by means of the controller 90, which controls the servo valve 84 and which is supplied with a position deviation dx formed by a subtractor 91 as an input variable, the position deviation resulting from the difference in the actual position x of the longitudinal stop 50, measured by the position measuring apparatus 70, and a position control variable (setpoint position) x.sub.F that is predefined and stored in the device. The position control variable is a constant value during the actual shearing operation. Based on the position deviation dx, the controller 90 controls, by means of the servo valve 84, the hydraulic pressures in the piston chamber 63 in such a way that the position deviation dx is minimized, and in the ideal case disappears, and the longitudinal stop 50 thus assumes or maintains its position predefined by the control variable x.sub.F. Conversely, due to the position-controlled action of force on the end section R.sub.E, the end section R.sub.E may also be prevented from being compressed to an undesirably high level due to an excessive axial action of force.
(35) The target length of the end section R.sub.E to be sheared may also be set by means of the position control of the longitudinal position of the longitudinal stop 50. For this purpose, before the actual shearing operation begins, the longitudinal stop 50 is moved in the longitudinal direction, based on the control variable x.sub.F stored in the device, into a position that corresponds to the desired target length of the end section R.sub.E.
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(38) According to one particularly advantageous exemplary embodiment of the device according to the invention schematically illustrated in
(39) The components bordered by dash-dotted lines in
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(41) The shear path or shearing stroke s of the shearing blade is plotted on the abscissa in
(42) Curve f1 in
(43) The longitudinal position p of the longitudinal stop 50 is plotted on the right ordinate in
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(46) The shearing method according to the invention explained above, with action of pressure force on the end section to be sheared with a position-controlled longitudinal position of the longitudinal stop, results in a significant reduction in the machine load with nonetheless high quality of the shear surface, and at the same time avoids the risk of undesirable compression of the end section. However, depending on the material, dimensions, and temperature of the rod material, it is possible that the desired shearing quality is not achieved with this position-controlled action of pressure force. In this case, according to another important aspect of the invention, a change is made to force-controlled action of pressure force (
(47) In
(48) Further variations of the devices and methods described above may be implemented. In particular, the evaluation of the course of the stop force for assessment of the shearing quality, and the selection of the control strategy (position control/force control), could also take place in an automated manner by computer control.
(49) The shearing method according to the invention and the corresponding device according to the invention are usable in conjunction with forming processes over the entire temperature range of hot forming, to forming at lowered temperature, all the way to cold forming.