Device and method for leveling a metal plate

Abstract

A device to level a metal plate fabricated from high-strength steel material includes a frame, a leveling station and a draw device. The leveling station includes a plurality of upper and lower rollers in parallel arrangement and defining a serpentine path. A plunge depth is defined based upon a difference between a top-dead-center point of the lower rollers and a bottom-dead-center point of contiguous upper rollers. A longitudinal spacing and the plunge depth are configured such that the upper rollers and the lower rollers are disposed to impart a bend radius on the metal plate as the metal plate is drawn, via the draw device, through the serpentine path such that the metal plate conforms to the outer peripheral surfaces of the upper rollers and the lower rollers. The bend radius is selected to achieve plastification of the metal sheet.

Claims

1. A device configured to level a metal plate fabricated from high-strength metal material, the device comprising: a frame; a leveling station including one pair of upper rollers and a corresponding one pair of lower rollers rotatably disposed on the frame in a parallel arrangement in a lateral direction and defining a serpentine path that is disposed in a longitudinal direction that is associated with a direction of travel for the metal plate; and wherein each one of the one pair of upper rollers includes a cylindrical outer peripheral surface that extends in the lateral direction and radially surrounds an upper axis of rotation; wherein each one of the one pair of lower rollers includes a cylindrical outer peripheral surface that extends in the lateral direction and radially surrounds a lower axis of rotation; wherein the radii of each one of the one pair of upper rollers and the radii of each one of the one pair of lower rollers are equivalent; wherein the upper axes of rotation are offset in the longitudinal direction from the lower axes of rotation such that a longitudinal spacing is defined between the axes of rotation of contiguous ones of the one pair of upper rollers and the one pair of lower rollers; wherein a plunge depth is defined as a difference in an elevation direction between a first elevation associated with a top-dead-center point of each one of the one pair of lower rollers and a second elevation that is associated with a bottom-dead-center point of each one of the one pair of upper rollers; wherein the magnitude of the plunge depth associated with each one of the one pair of upper rollers and one of the one pair of lower rollers that is longitudinally disposed between the one pair of upper rollers is equal to the magnitude of the plunge depth associated with each one of the one pair of lower rollers and one of the one pair of upper rollers that is longitudinally disposed between the one pair of lower rollers; wherein the serpentine path is defined between the outer peripheral surfaces of contiguous ones of the one pair of upper rollers and the one pair of lower rollers; wherein the longitudinal spacing of each one of the one pair of upper rollers and each one of the one pair of lower rollers is equal to achieve the equal plastification on the first and second sides of the metal plate; wherein the longitudinal spacing and the plunge depth are configured such that the one pair of upper rollers and the one of the one pair of lower rollers that is longitudinally disposed between the one pair of upper rollers imparts a first bend radius on the metal plate in a first orientation and the one pair of lower rollers and the one of the pair of upper rollers that is longitudinally disposed between the one pair of lower rollers subsequently imparts a second bend radius on the metal plate in a second orientation that is opposed to the first orientation as the metal plate moves through the serpentine path as the metal plate bends about a portion of the outer peripheral surfaces of each one of the one pair of upper rollers and each one of the one pair of lower rollers to subject the metal plate to plastic deformation corresponding to the portion of the respective outer peripheral surfaces of each one of the one pair of upper rollers and each one of the one pair of lower rollers to provide equal plastification on both sides of the metal plate; wherein the magnitude of the first bend radius and the magnitude of the second bend radius is selected such that a magnitude of plastification of the metal plate that is greater than 70% is achieved once the metal plate moves along the serpentine path past the two upper rollers and the two lower rollers; and wherein the magnitude of the first bend radius is equivalent to the magnitude of the second bend radius; and wherein there is a quantity of not more than the one pair of upper rollers and a quantity of not more than the one pair of lower rollers to achieve equal plastification on both sides of the metal plate.

2. The device of claim 1, wherein each bend radius is selected such that a magnitude of plastification of the metal plate that is greater than 90% is achieved once the metal plate moves along the serpentine path past the two upper rollers and the two lower rollers.

3. The device of claim 1, wherein the bend radius is determined as a function of a modulus of elasticity of the material of the metal plate, a thickness of the metal plate, the magnitude of plastification of the metal plate, and a yield strength of the material of the metal plate.

4. The device of claim 3, wherein each bend radius is determined as a function of a yield strength of the metal material of the metal plate being greater than 50,000 psi.

5. The device of claim 1, wherein the longitudinal spacing, the upper rolling radii, lower rolling radii, and the plunge depth are configured such that as the metal plate moves through the serpentine path in the longitudinal direction, the pair of upper rollers impart a first bending stress on a first side of the metal plate and the pair of lower rollers impart a second bending stress on a second side of the metal plate, opposite the first side, such that the first and second bending stresses are equal to provide equal plastification on the first and second sides of the metal plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1-1 and 1-2 are schematic illustrations of a leveler that is capable of leveling a high-strength metal sheet, including a coil feeder device, a leveling station, an anti-crossbow station, an anti-coilset station and a draw device that are shown in context of an elevation direction, a lateral direction and a longitudinal direction, in accordance with the disclosure;

(2) FIG. 2 is a graphical illustration of a stress/strain relationship for metals, depicting modulus of elasticity, elastic deformation, yield strength and plastic deformation for select metal alloys, in accordance with the disclosure;

(3) FIG. 3 schematically shows a side-view of a portion of a high-strength metal sheet that is being drawn across a roller in the longitudinal direction at a first bending radius such that the metal sheet conforms to the roller, in accordance with the disclosure; and

(4) FIG. 4 schematically shows a side-view of a portion of a high-strength metal sheet that is being drawn across a roller in the longitudinal direction at a second bending radius such that the metal sheet conforms to the roller, in accordance with the disclosure.

DETAILED DESCRIPTION

(5) The components of the disclosed embodiments, as described and illustrated herein, may be arranged and designed in a variety of different configurations. Thus, the following detailed description is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments thereof. In addition, while numerous specific details are set forth in the following description in order to provide a thorough understanding of the embodiments disclosed herein, some embodiments can be practiced without some or all of these details. Moreover, for the purpose of clarity, certain technical material that is known in the related art has not been described in detail in order to avoid unnecessarily obscuring the disclosure. Furthermore, the drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms such as top, bottom, left, right, up, down, upper, lower, upward and downward may be used with respect to the drawings. These and similar directional terms are not to be construed to limit the scope of the disclosure in any manner. Furthermore, the disclosure, as illustrated and described herein, may be practiced in the absence of any element that is not specifically disclosed herein.

(6) Referring to the drawings, wherein like reference numbers refer to like components throughout the several Figures, a side-view of a leveler 10 that is capable of leveling a metal sheet 25 that has been fabricated from high-strength materials is shown schematically in FIGS. 1-1 and 1-2. The metal sheet 25 may be in the form of a metal strip, coiled material, or a plate, and leveling is the process by which a leveling machine, i.e., the leveler 10 flattens the metal sheet 25 to comply with a flatness specification. The terms plate and sheet are used interchangeably throughout this disclosure. The leveler 10 preferably includes a coil feeder device 12, a leveling station 20, an anti-crossbow station 14, an anti-coilset station 16, and a draw device 18, all of which are shown in context of a coordinate system that includes an elevation direction 11, a longitudinal direction 13 and a lateral direction 15. A direction of travel 17 associated with movement of the metal sheet 25 through the leveler 10 is indicated, and The coil feeder device 12 may be any suitable device capable of uncoiling the metal sheet 25 when it is supplied in coiled form. The coil feeder device 12 is preferably configured so that it only exerts a de minimis tensile force on a first end 26 of the metal sheet 25 that is related to uncoiling the metal sheet 25. The draw device 18 may be any suitable device that is capable of exerting a pull force on a second end 27 of the metal sheet 25, and is shown as a unitary device for ease of illustration. The anti-crossbow station 14 and the anti-coilset station 16 may be any suitable devices that are capable of accomplishing their respective tasks.

(7) The leveling station 20 of the leveler 10 is advantageously configured to level a metal plate that is fabricated from high-strength steel, e.g., the metal sheet 25 described herein, by bending the metal sheet 25 up and down as it is drawn along a serpentine path 28 over interrupting arcs of upper and lower sets of rollers. The process of successively alternating the bends of the metal sheet 25 stretches both sides of the metal sheet 25 beyond elastic limits to effect leveling. The leveling station 20 preferably includes a frame portion 24 that is preferably disposed on a ground surface 22 to support a plurality of upper rollers 30, 35 and a plurality of lower rollers 40, 45. As shown, a quantity of two upper rollers 30, 35 and a corresponding quantity of two lower rollers 40, 45 are supported and employed. Alternatively, any quantity of the upper rollers 30, 35 and the lower rollers 40, 45 may be employed, so long as there is an equal quantity of each. The upper rollers 30, 35 and the lower rollers 40, 45 are rotatably disposed on the frame 24 in parallel arrangement in the lateral direction 15 using suitable bearings, axles and related hardware. Preferably, the upper rollers 30, 35 and the lower rollers 40, 45 are rotatably disposed on the frame 24 in a freewheeling manner. The upper rollers 30, 35 and the lower rollers 40, 45 define the serpentine path 28, which is oriented in the longitudinal direction 13.

(8) Each of the upper rollers 30, 35 extends in the lateral direction 15. As indicated, the upper roller 30 defines an axis of rotation 31, and includes an axle 32 and a cylindrical outer peripheral surface 33 surrounding the axis of rotation 31 that define an upper roller radius 34. The upper roller 35 includes analogous elements, including an axis of rotation 36. The upper rollers 30, 35 are disposed such that their axes of rotation 31, 36 are both disposed at a first height 50 relative to the ground surface 22.

(9) Each of the lower rollers 40, 45 also extends in the lateral direction 15 in parallel with the upper rollers 30, 35. As indicated, the lower roller 40 defines an axis of rotation 41, and includes an axle 42 and a cylindrical outer peripheral surface 43 surrounding the axis of rotation 41 that define a lower roller radius 44. The lower roller 45 includes analogous elements, including an axis of rotation 46. The lower rollers 40, 45 are disposed such that their axes of rotation 41, 46 are both disposed at a second height 52 relative to the ground surface 22.

(10) The axes of rotation 31, 36 of the upper rollers 30, 35, respectively are offset in the longitudinal direction 13 from the axes of rotation 41, 46 of the lower rollers 40, 45, respectively, such that longitudinal spacings are defined between the axes of rotation of the contiguous ones of the upper and lower rollers. As shown, this includes a first longitudinal spacing 47 between the axis of rotation 31 and the axis of rotation 46, a second longitudinal spacing 48 between the axis of rotation 46 and the axis of rotation 36, and a third longitudinal spacing 49 between the axis of rotation 36 and the axis of rotation 41. Preferably, the first, second and third longitudinal spacings 47, 48 and 49 are equal in length.

(11) A leveling plane 38 is indicated, and is a nominally neutral plane associated with the serpentine path 28 that extends in the lateral and longitudinal directions 15, 13. A plunge depth 54 is shown in the elevation direction 11, and is related to a difference between top-dead-center points 59, 57 of the lower rollers 40, 45, respectively, and bottom-dead-center points 56, 58 of the upper rollers 30, 35, respectively. In one embodiment, the plunge depth 54 may be defined based upon a difference between a first elevation 53 that is associated with the top-dead-center points 59, 57 of the lower rollers 40, 45 and a second elevation 55 that is associated with the bottom-dead-center points 56, 58 of the upper rollers 30, 35. The plunge depth 54 may be determined based a difference between the top-dead-center points of the lower rollers 40, 45 and the bottom-dead-center points of contiguous ones of the upper rollers 30, 35, upon the first and second elevations 53, 55 and the upper roller radius 34 and the lower roller radius 44. The serpentine path 28 is defined between the outer peripheral surfaces 33, 43 of contiguous ones of the upper rollers 30, 35 and the lower rollers 40, 45.

(12) The leveling station 20 is configured such that the longitudinal spacings 47, 48 and 49, the plunge depth 55, the upper roller radius 34 and the lower roller radius 44 impart a desired bend radius on the metal plate 25 as the metal plate 25 is drawn through the serpentine path 28 such that the metal plate 25 conforms to the outer peripheral surfaces 33, 43 of the upper rollers 30 and the lower rollers 40, 45. The metal plate 25 is preferably subjected to plastic deformation when it conforms to the outer peripheral surfaces 33, 43 of the upper rollers 30, 35 and the lower rollers 40, 45. This includes the longitudinal spacings 47, 48 and the plunge depth 55 being configured to impart a first bend radius 62 on the metal plate 25 in a first orientation, e.g., downward as shown. This also includes the longitudinal spacings 48, 49 and the plunge depth 55 being configured to impart a second bend radius 64 on the metal plate 25 in a second orientation that is opposed to the first orientation, e.g., upward as shown. Preferably, the magnitude of the first bend radius 62 is equivalent to the magnitude of the second bend radius 64.

(13) The leveling station 20 employs the upper rollers 30, 35 and the lower rollers 40, 45 to successively alternate the bending of the metal plate 25 as it is drawn through the serpentine path 28 to plastically elongate a first outer area of the metal plate 25 that is located on a first surface thereof, and plastically elongate a second outer area of the metal plate 25 that is located on a second, opposite surface thereof.

(14) When a relatively small force is applied to a material it deforms a little, with the deformation being linearly proportional to the applied force, which is called the modulus of elasticity, or Young's modulus. For steel the modulus of elasticity is approximately one divided by 30 million psi (1/30E6 psi). For aluminum, the modulus of elasticity it is about one divided by ten million psi (1/10E6 psi). The modulus of elasticity applies when the material is stressed low enough to return to its original shape when the force is released. If the metal is never stressed beyond its elastic range, the metal will never permanently change shape. However, stressing metal beyond its elastic range causes it to become plastic, i.e., to permanently deform. This occurs when the applied stress reaches or exceeds a yield strength of the material.

(15) The leveler 10 employs bending to subject the metal sheet 25 to bending stress that is greater than its yield strength, thus plastifying at least a portion of the metal sheet 25 to effect its leveling. The bending is achieved by drawing the metal sheet 25 through the serpentine path 28 to subject the metal sheet 25 to bending stress that is greater than its yield strength.

(16) By way of a non-limiting example, one embodiment of the leveling station 20 may be configured with each of the upper rollers 30, 35 and the lower rollers 40, 45 having a radius of 0.75 inches and arranged at a longitudinal spacing of 3.375 inches with a plunge depth of 1.25 inches to achieve a bend radius of less than 0.875 inches for a steel sheet that is 0.080 inches thick and 60 inches wide with a 100,000 psi yield strength. This arrangement can generate plastification of the steel sheet that is greater than 90%, and require a draw force of approximately 70,000 pounds. Overall, the bend radius is greater than or equal to the roller radius. Thinner gauge metal sheets require a higher bend radius, which leads to smaller roller radius. This concept applies to steel and other metal alloys of any magnitude of yield strength.

(17) FIG. 2 graphically illustrates a stress/strain relationship for various metals, with the horizontal axis 105 indicating strain or elongation, and the vertical axis 110 indicating stress, or force on the metals. Results associated with three metals are shown, including a modulus of elasticity and a yield strength for a first metal 111, a second metal 113 and a third metal 115. The first metal 111, known in the industry as A-36, is characterized in terms of a modulus of elasticity 120 of about 1/30E6 psi, an elastic deformation portion 112, a yield strength 121 of about 36,000 psi, and a plastic deformation portion 122. The second metal 113, known in the industry as X70, is characterized in terms of a modulus of elasticity 120 of about 1/30E6 psi, an elastic deformation portion 125, a yield strength 123 of about 70,000 psi, and a plastic deformation portion 124. The third metal 115, known in the industry as AR500, is characterized in terms of a modulus of elasticity 120 of about 1/30E6 psi, an elastic deformation portion 114, a yield strength 127 of about 180,000 psi, and a plastic deformation portion 128. The third metal 115 has an elastic limit or yield strength that is five times greater than that of the first metal 111. The second metal 113 and the third metal 115 are high-strength steel materials, wherein the term high-strength is assigned based upon the associated yield strength.

(18) A bend radius can be defined for a metal sheet, in relation to various factors, as follows:
Rs=E*T/k*Ys[1]

(19) wherein: Rs is the bend radius (inches), E is the modulus of elasticity (psi), T is the thickness of the metal sheet (inches), k is a scalar term associated with the desired magnitude of plastification of the metal sheet, and Ys is the yield strength of the metal (psi).

(20) The term plastification and related terms refer to plastically elongating an element, e.g., a metal sheet, including subjecting the metal sheet to stress that is in excess of its elastic limit, and may be defined in terms of a portion (%) of a cross-sectional area of the metal sheet. As such, a metal sheet that has only been subjected to stress that is less than its elastic limit has a 0% plastification, and a metal sheet that has been completely subjected to stress that is greater than its elastic limit has a 100% plastification.

(21) Referring again to FIG. 2, the third metal 115 exhibits a yield strength 127 of about 180,000 psi, which is a factor of five greater than the yield strength 121 of the first metal 111. As such, the third metal 115 requires a bend radius that is five times smaller than the bend radius of the first metal 111 to achieve the same magnitude of plastification.

(22) As the yield strength increases the bend radius, the required draw force increases at a linear rate. In this case it is a 5:1 ratio for A36 and 180000 yield materials. However, the plunge depth 55 required to achieve the desired magnitude of plastification is non-linear. Thinner gauge steel require a greater increase in plunge depth as the yield strengths increase as compared to thicker gauges. This requires the roll diameter to get smaller as the yield strengths increase for thin gauge steel.

(23) FIG. 3 schematically shows a side-view of a portion of a high-strength metal sheet 200 that is being drawn across a roller 210 in the longitudinal direction 13, such that the metal sheet 200 conforms to the roller 210 at a first bending radius 220, with the metal sheet 200 and roller 210 extending in the lateral direction 15. The metal sheet 200 is characterized in terms of a thickness 202, and is described in terms of a centerline 201, an inner surface 203 and an outer surface 206, wherein the inner surface 203 is that portion of the metal sheet 200 that is proximal to the roller 210 and the outer surface 206 is that portion of the metal sheet 200 that is distal from the roller 210. The roller 210 is analogous to one of the upper or lower rollers 30, 40 that is described with reference to FIG. 1, and includes an axis of rotation 214 and a cylindrical outer peripheral surface 215 surrounding the axis of rotation 214 that define a roller radius 212. A direction of travel 216 is shown, and indicates the direction that the metal sheet 200 is being drawn.

(24) The metal sheet 200 includes areas of stress deformation 222 and an area of conformance 224 as the metal sheet 200 is drawn across the roller 210 and is subject to bending in conformance with the roller 210. The areas of stress deformation 222 include an inner portion 204 that is adjacent to the inner surface 203 and an outer portion 207 that is adjacent to the outer surface 206. The first bending radius 220 is determined in accordance with EQ. 1.

(25) When the metal sheet 200 is subjected to forces that achieve the first bending radius 220, the areas of stress deformation 222 may be defined in terms of an inner portion 204, a neutral portion 205 and an outer portion 207. The outer portion 207 delineates that portion of the cross-sectional area of the metal sheet 200 that is subject to bending that is sufficient to be plastically elongated. The inner portion 204 delineates that portion of the cross-sectional area of the metal sheet 200 that is subject to bending that is sufficient to be plastically compressed, and also be plastically elongated when bent in an opposed direction. The neutral portion 205 is only subjected to elastic bending. The inner portion 204 and the outer portion 207 define the magnitude of plastification of the metal sheet 200, which may be in the order of magnitude of 50% as shown.

(26) FIG. 4 schematically shows a side-view of a portion of a high-strength metal sheet 300 that is being drawn across a roller 310 in the longitudinal direction 13 at a second bending radius 320 such that the metal sheet 300 conforms to the roller 310, with the metal sheet 300 and roller 310 extending in the lateral direction 15. The metal sheet 300 is characterized in terms of a thickness 302, and is described in terms of a centerline 301, an inner surface 303 and an outer surface 306, wherein the inner surface 303 is that portion of the metal sheet 300 that is proximal to the roller 310 and the outer surface 306 is that portion of the metal sheet 300 that is distal from the roller 310. The roller 310 is analogous to one of the upper or lower rollers 30, 40 that is described with reference to FIG. 1, and includes an axis of rotation 314 and a cylindrical outer peripheral surface 315 surrounding the axis of rotation 314 that define a roller radius 312. A direction of travel 316 is shown, and indicates the direction that the metal sheet 300 is being drawn.

(27) The metal sheet 300 includes areas of stress deformation 322 and an area of conformance 324 as the metal sheet 300 is drawn across the roller 310 and is subject to bending in conformance with the roller 310. The areas of stress deformation 322 include an inner portion 304 that is adjacent to the inner surface 303 and an outer portion 307 that is adjacent to the outer surface 306. The second bending radius 320 is determined in accordance with EQ. 1.

(28) When the metal sheet 300 is subjected to forces that achieve the first bending radius 320, the areas of stress deformation 322 may be defined in terms of an inner portion 304, a neutral portion 305 and an outer portion 307. The outer portion 307 delineates that portion of the cross-sectional area of the metal sheet 300 that is subject to bending that is sufficient to be plastically elongated. The inner portion 304 delineates that portion of the cross-sectional area of the metal sheet 300 that is subject to bending that is sufficient to be plastically compressed, and also be plastically elongated when bent in an opposed direction. The neutral portion 305 is only subjected to elastic bending. The inner portion 304 and the outer portion 307 define the magnitude of plastification of the metal sheet 300, which may be in the order of magnitude of 90% for the bending radius 320.

(29) As such, bending is achieved by controlling the plunge depth 55 and the longitudinal spacings between the axes of rotation of the contiguous ones of the upper and lower rollers. Decreasing the bending radius from the first bending radius 220 shown with reference to FIG. 3 to the second bending radius 320 shown with reference to FIG. 4 results in an increase in the plastification of the associated metal sheet.

(30) While the best modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims.