Method and apparatus for forming the profile of deformable materials and deformable tubular sections

Abstract

An apparatus for forming the profile of deformable materials including tubular sections. The apparatus (1) includes at least two sets (4, 5) of die elements (6), each set (4,5) including a plurality of die elements (6) respectively arranged to travel along corresponding endless path. The paths each include a forming portion (9,10) in which die elements (6) of each set (4. 5) are opposed to define a forming space (11) therebetween. The forming portion (9, 10) of each path is configured so that one or more dimensions of the forming space (11) reduce along the length of the forming portion (9,10) to simultaneously apply lateral forces to material progressing through the forming portion.

Claims

1. An apparatus for forming the profile of deformable materials, said apparatus comprising: at least two sets of die elements arranged for synchronized movement with respect to each other, each set including a plurality of die elements respectively arranged to travel along corresponding endless paths; said paths each including a forming portion in which die elements of each set are opposed to define a forming space therebetween; and the forming portion of each path being configured so that one or more dimensions of the forming space reduce along a length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape said material to a determined profile and so that at least one of the forming portions of the paths is formed as a large radius curve, wherein a ratio of a pitch between each die in the forming portion of the path and the radius of the path is over 1:500, and wherein each die element has a base and a forming surface spaced from the base, the dies being configured so that any section taken perpendicular to the base of the die has along the longitudinal axis a constant depth from the base to the longitudinal axis and a constant depth from the forming surface to the longitudinal axis so that in each respective section the depth is the same along the forming surface of the die element, such that each of the opposing die elements define flat, planar forming surfaces.

2. The apparatus according to claim 1, wherein each of the opposed forming portions are formed as a large curvature radius.

3. The apparatus according to claim 2, wherein curvature centres of radii of the opposed forming portions are on respectively opposite sides of the corresponding forming portions.

4. The apparatus according to claim 2, wherein respective curvature centres of radii of the opposed forming portions are on a same side of the forming portions.

5. The apparatus according to claim 1, wherein the radius of at least one large radius curve is variable over the forming portion.

6. The apparatus of claim 1, wherein the die elements are arranged in a form of an endless chain with each die element forming or attached to a link connected to one or more adjacent links.

7. An apparatus for forming the profile of deformable materials, said apparatus comprising: at least one set of die elements including a plurality of die elements arranged to travel along an endless path; a moving forming surface arranged to travel about a corresponding endless path, the dies and the forming surface being arranged for synchronized movement with respect to each other; said paths each including a forming portion in which die elements are to opposed to said forming surface to define a forming space therebetween; the forming portion of each path being configured so that one or more dimensions of the forming space reduce along a length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape said material to a determined profile and so that at least one of the forming portions of the paths is formed as a large radius curve, wherein a ratio of a pitch between each die in the forming portion of the path and the radius of the path is over 1:500, and wherein each die element has a base and a forming surface spaced from the base, the dies being configured so that any section taken perpendicular to the base of the die has along the longitudinal axis a constant depth from the base to the longitudinal axis and a constant depth from the forming surface to the longitudinal axis so that in each respective section the depth is the same along the forming surface of the die element, such that each of the opposing die elements define flat, planar forming surfaces.

8. A method of forming the profile of deformable materials, said method comprising: passing the material through a forming space between moving die elements; the die elements being configured in at least two sets, each set including a plurality of die elements respectively arranged to travel along corresponding endless paths; said paths each including a forming portion in which die elements of each set are opposed to define said forming space therebetween; the forming portion of each path being configured so that one or more dimensions of the space reduce along a length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape said material to a determined profile, wherein each of the opposed forming portions are formed as a large radius curve and a ratio of a pitch between each die in the forming portion of the path and the radius of the path is over 1:500, and wherein each die element has a base and a forming surface spaced from the base, the dies being configured so that any section taken perpendicular to the base of the die has along a longitudinal axis a constant depth from the base to the longitudinal axis and a constant depth from the forming surface to the longitudinal axis so that in each respective section the depth is the same along the forming surface of the die element, such that each of the opposing die elements define flat, planar forming surfaces.

9. The method according to claim 8, wherein curvature centres of radii of each of the large radius curves are on respectively opposite sides of the corresponding forming portions.

10. The method according to claim 8, wherein the respective curvature centres of radii are on a same side of the forming portions.

11. The method according to claim 8, wherein at least one of the radii of the large radius curves is variable over the forming portion.

12. The apparatus according to claim 1, wherein the deformable material is a tubular section.

13. The apparatus of claim 12, wherein the forming portions are arranged such that the die elements of the at least two sets act substantially directly opposite each other against respective sides of the tubular section.

14. The apparatus of claim 13, further comprising four sets of die elements arranged to form two substantially directly opposed pairs in the forming portion.

15. The method of claim 8, wherein the deformable material is a tubular section.

16. The method of claim 15, wherein there are four sets of die elements arranged to form two substantially directly opposed pairs in the forming portion.

17. An apparatus according to claim 7, comprising three sets of die elements, the die elements configured to cooperate with the moving forming surface to progressively form the deformable material into the determined profile.

18. An apparatus for forming the profile of deformable materials, said apparatus comprising: at least two sets of die elements arranged for synchronized movement with respect to each other, each set including a plurality of die elements respectively arranged to travel along corresponding endless paths; said paths each including a forming portion in which die elements of each set are opposed to define a forming space therebetween; and the forming portion of each path being configured so that one or more dimensions of the forming space reduce along a length of the forming portion to simultaneously apply lateral forces to material progressing through the forming portion to shape said material to a determined profile and so that at least one of the forming portions of the paths is formed as a large radius curve, wherein a ratio of a pitch between each die in the forming portion of the path and the radius of the path is over 1:500, wherein the dies of each set are arranged in synchronised sections of opposing dies, the dies in each section having a non-uniform profile and cooperating to progressively form a determined profile having a longitudinal taper, and wherein each die element has a base and a forming surface spaced from the base, the dies being configured so that any section taken perpendicular to the base of the die has along a longitudinal axis a constant depth from the base to the longitudinal axis and a constant depth from the forming surface to the longitudinal axis so that in each respective section the depth is the same along the forming surface of the die element, such that each of the opposing die elements define flat, planar forming surfaces.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic elevation of an apparatus for forming the profile of deformable sheet material according to an embodiment of the invention;

(2) FIG. 2 is a schematic perspective view of the apparatus shown in FIG. 1;

(3) FIG. 3(a) is a schematic perspective view of an apparatus for forming the profile of deformable tubular sections according to an embodiment of the invention;

(4) FIG. 3(b) is a schematic elevation of part of the apparatus shown in FIG. 3(a);

(5) FIG. 4(a) schematically illustrates a configuration of dies suitable for use in the embodiment of FIGS. 1 and 2;

(6) FIGS. 4(b) and 4(c) schematically illustrates a configuration of dies suitable for use in the embodiment of FIG. 3;

(7) FIGS. 5(a) to 5(c) schematically illustrate a modification to the embodiment of FIGS. 1 and 2,

(8) FIGS. 6(a) to 6(c) schematically show different driving mechanisms applicable to the embodiments of both FIGS. 1 and 2 and FIG. 3;

(9) FIGS. 7(a) to 7(d) schematically show track configurations applicable to the embodiments of both FIGS. 1 and 2 and FIG. 3;

(10) FIG. 8 schematically shows the relationship between maximum gap between adjacent dies and the radius of the forming portion of the track applicable to the embodiments of both FIGS. 1 and 2 and FIG. 3;

(11) FIGS. 9(a) to 9(c) shows some of the profiles that can be formed from a circular section using the embodiment of FIG. 3; and

(12) FIG. 10 schematically shows a set of dies used in a extensive application of the apparatus of FIGS. 1 and 2.

BEST MODES FOR CARRYING OUT THE INVENTION

(13) Referring to the FIGS. 1 and 2 a schematic configuration of the apparatus for forming the profile of deformable sheet material is shown. The apparatus 1 includes two track frames 2, 3 that mount respective sets 4, 5 of die elements 6. The die elements 6 have any suitable profile determined by the profile desired to be formed. In the illustrated embodiment respective male and female die sets suitable for forming a channel or a top-hat profile are shown. Each die element 6 is mounted on a chain link 7 respectively connected to the adjacent chain link 7 by a pin 8 in a conventional manner to form a roller chain. The track frames 2, 3 define respective endless paths or tracks around which the links 7 travel. Each of the paths has a forming portion 9, 10 in which the die elements 6 of each set are opposed to define a forming space 11. Other than in the forming portion, it is not necessary for the chain links 7 to contact the track frame. The forming portions 9, 10 are configured so that the dimensions of the space 11 between the forming portions reduce along its length. In this way transverse forces are simultaneously applied to a section passing through the forming portion. The die elements 6 move with the material synchronisely and the distance between the sets of elements 6 gradually reduces.

(14) FIG. 3 shows an embodiment of the invention for forming the profile of a deformable hollow section from a pre-formed tubular section. The same reference numerals as used in relation to FIGS. 1 and 2 have been used to identify corresponding integers. The apparatus 1 includes four track frame elements 2, 2a, 3, 3a arranged in opposed pairs. Each track frame element mounts respective sets 4, 4a, 5, 5a of die elements 6. The die elements 6 have any suitable profile determined by the profile desired to be formed in the material. Each die element 6 is mounted on a chain link 7 respectively connected to the adjacent chain link 7 by a pin 8 in a conventional manner to form a roller chain. The track frames 2, 2a, 3, 3a define respective endless paths around which the links 7 travel. Each of the paths has a forming portion 9, 9a, 10, 10a in which the die elements 6 associated with each pail of track frames are opposed to define a forming space 11. The forming portions 9, 9a, 10, 10a are configured so that the dimensions of the space 11 between the forming portions reduce along its length. In this way transverse forces are simultaneously applied to a section passing through the forming portion. This can be visualised as the section to be formed being forced through a progressively smaller aperture as it progresses through the forming portion.

(15) FIGS. 4(a) to 4(c) show three different configurations of die elements 6 profiles at respective locations along the formed portion 10. FIG. 4(a) shows a configuration applicable to the embodiment shown in FIGS. 1 and 2 for forming the profile of a deformable sheet material m. The die sets are made up of respective male and female opposed dies. As the dies move along the forming portions 9, 10 the distance between them decreases to reduce the forming space in the direction from right to left. This progressively forms the material to a desired profile.

(16) FIGS. 4(b) and 4(c) show a configuration of die sets used in the embodiment generally described in relation to FIG. 3. In FIG. 4(b) four die sets arranged in opposed pairs are used to form a circular section h into a square section as the dies move together along the forming space. FIG. 4(c) shows an arrangement in which three sets of dies displaced at 120 to form a circular section h to a triangular profile.

(17) FIG. 5 shows an alternative to the apparatus shown in FIGS. 1 and 2. In this configuration one lower set 12 of die elements 6 have the profile of the final die profile. Three upper sets 6 of progressive shaped complimentary die elements upon track frames 2 are sequentially positioned. In the same manner as described in relation to FIGS. 1 and 2 this provides forming portions 9, 10 at three spaced apart locations. In the same way as described above the forming portions of the tracks are configured to progressively reduce the dimensions to the space 11 between the dies. The material m to be formed progressively proceeds from right to left as shown in the drawings and is formed to the desired profile by the sequential operation of the die sets.

(18) FIGS. 6(a) to 6(c) show souse exemplary ways in which the apparatus can operate. In FIG. 6(a) the system is provided with driving sprockets which drive the two sets of die elements in phase so as to draw a section through the forming portion. In FIG. 6(b) separate set of driving rolls is provided to propel this section through the forming portion. FIG. 6(c) shows a similar configuration in which a separate set of driving rolls are used to push a section through the forming portion.

(19) FIGS. 7(a) to 7(d) show some of the possible configurations of the track in the forming portion of the apparatus. In FIG. 7(a) each of the opposed forming portions has a large radius and the centre of the radii are respectively on the opposite sides of the forming space. FIG. 7(b) shows configuration in which one of the forming portions has a large radius and another has an infinite radius or in other words is flat. FIG. 7(c) shows a configuration in which the centres of the radii are both on one side of the forming, space and large radii are used for the respective forming portions to provide converging paths between the opposed dies. FIG. 7(d) shows a configuration in which the radii of the forming portion is not constant to provide a converging track between the opposed dies.

(20) FIG. 8(a) schematically shows the relationship between the maximum gap between adjacent dies on the chain and the radius of the portion of the track. In accordance with the invention the pitch to radius ratio is large and preferably over 1:500. As shown in the diagram the maximum gap between the adjacent dies is approximately the product of the height and the length divided by the radius of the track. The distance s the chord height between cord c extending through the mid point of the upper die surface and the adjacent die corners is a measure of the relative angle between the die blocks. It is approximately equal to the square of the length of each die divided by quad the radius. It will be apparent that larger gaps may occur in portions of the track other than the forming portion without in any way affecting the operation of the apparatus.

(21) FIGS. 9(a) to 9(c) schematically shows some of the profiles that can be formed from a circular section using the apparatus of this invention. FIG. 9(a) shows a triangular profile. FIG. 9(b) shows a rectangular profile and FIG. 9(c) a stepped profile. It will be apparent however that appropriate selection of die shapes can produce a wide range of profiles.

(22) FIG. 10 shows a modified form of the die sets suitable for use in the invention as described in FIGS. 1 and 2. As shown in the drawings the die elements 6 are not uniform but form a taper. By arranging these dies in sections on corresponding parts of the respective tracks a profile having a longitudinal taper or other desired non linear form can be formed.

(23) Embodiments of this invention can be in the form of standalone equipment lined before or after a forming process such as roll forming to process auxiliary operations such as blanking, punching, doming, coining, shearing and the like. Because the forming dies' velocity is so close to the strip's velocity, the auxiliary operation is processed continuously without the interference with the strip that occurs in the rotary punching or doming.

(24) FIGS. 11 (a) and 11 (b) schematically show die configurations for performing punching and doming respectively. As in the other embodiments opposed dies corresponding shaped to perform the operation more through a forming function in which the dimension of the forming space reduce along the length of the forming portion.

(25) In the embodiments discussed above, one part of the die elements (for example, male die elements), are rigid to ensure the profile to be formed but the another can be elastically deformable such as using polyurethane. The deformable die elements can provide adequate compressing force to the material to be formed and/or compensate the variation of material properties and thickness.

(26) Embodiments of the invention can also be used to form a part having limited length that requires multiple passes to form. As schematically shown in FIG. 12 the forming dies for each pass (for example, 8 passes as shown) are arranged in one set and the motions of the sets are synchronised. The blank is fed into the former a corresponding number of times to achieve the final profile in one machine. One advantage of this arrangement is to save the capital and space, and another is this type former can be placed beside an assembly line for multi component product and after forming a workpart on-site, the part can be assembled to the product directly.

(27) In the embodiment discussed, a guiding system can be a separate apparatus or embedded in the die-blocks. In order to avoid the sheet metal slip sideway, using magnetic die blocks in one die set can sufficiently control the steel strip moving straight forward. Other method such as guide plates assembled on the die-blocks may also be applied to guide the strip going straight.

(28) The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

(29) Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises and comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

(30) The foregoing describes only some embodiments and modifications can be made without departing from the scope of the invention.