Patent Application
20180093310
The present disclosure is related to a device and method of leveling a metal plate.
A metal plate may be subject to leveling to achieve a desired flatness that facilitates further processing of the metal plate. Metal plates fabricated from high-strength metals introduce added complexity to leveling due to increased elasticity and yield strengths.
One possible aspect of the disclosure provides for a method to effect leveling of a sheet of high-strength metal material employing a leveler. The method includes providing a serpentine path in a longitudinal direction between a plurality of upper rollers and a corresponding plurality of lower rollers that are rotatably disposed in a parallel arrangement in a lateral direction. The longitudinal direction is associated with a direction of travel for the metal plate. There are equivalent quantities of the plurality of upper rollers and the plurality of lower rollers. Each of the upper rollers includes an upper roller radius and an outer peripheral surface that define a bottom-dead-center point. Likewise, each of the lower rollers includes a lower roller radius and an outer peripheral surface that define a top-dead-center point. The serpentine path and the upper and lower rollers are disposed to accommodate the metal plate. The method also includes positioning the upper rollers in alternating relation to the lower rollers in the longitudinal direction such that a longitudinal spacing is defined between contiguous ones of the upper rollers and the lower rollers, and positioning the upper rollers relative to the lower rollers in an elevation direction, such that a plunge depth is defined as a difference in the elevation direction between the top-dead-center point of each one of the lower rollers and the bottom-dead-center point of a contiguous one of the upper rollers. The longitudinal spacing between contiguous ones of the upper and lower rollers and the plunge depth are configured to impart a bend radius on the metal plate when the metal plate is drawn through the serpentine path, such that each surface of the metal plate bends about a portion of the outer peripheral surfaces of each of the plurality of upper rollers and the plurality of lower rollers. The metal plate is drawn through the serpentine path in the longitudinal direction such that the bend radius is imparted on the metal plate as each surface of the metal plate bends about the portion of the outer peripheral surfaces of the respective upper rollers and the lower rollers to achieve a magnitude of plastification of the metal sheet that is greater than 70%.
Another possible aspect of the disclosure includes a device that is configured to level a metal plate fabricated from high-strength steel material. The device includes a frame, a leveling station and a draw device. The leveling station includes a plurality of upper rollers and a corresponding plurality of lower rollers that are rotatably disposed on the frame in parallel arrangement in a lateral direction and define a serpentine path that is disposed in a longitudinal direction that is associated with a direction of travel for the metal plate. The draw device is disposed to draw the metal plate through the serpentine path along the direction of travel. Each of the upper rollers includes a cylindrical outer peripheral surface that extends in the lateral direction and radially surrounds an upper axis of rotation, and each of the lower rollers includes a cylindrical outer peripheral surface that extends in the lateral direction and radially surrounds a lower axis of rotation. The upper axes of rotation are offset in the longitudinal direction from the lower axes of rotation such that an equidistant longitudinal spacing is defined between the axes of rotation of contiguous ones of the upper and lower rollers. A plunge depth is defined based upon a difference between a top-dead-center point of one of the lower rollers and a bottom-dead-center point of a contiguous one of the upper rollers. The serpentine path is defined between the outer peripheral surfaces of contiguous ones of the plurality of upper rollers and the plurality of lower rollers.
The 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 as the metal plate bends about a portion of the outer peripheral surfaces of each of the upper rollers and the lower rollers to subject the metal plate to plastic deformation corresponding to the portion of the respective outer peripheral surfaces of each of the upper rollers and the lower rollers. Each bend radius is selected such that a magnitude of plastification of the metal sheet that is greater than 70% is achieved once the metal sheet exits the leveling station.
Another aspect of the disclosure provides for the longitudinal spacing and the plunge depth being configured such that the upper rollers and the lower rollers are disposed to impart a first bend radius on the metal plate in a first orientation and disposed to impart a second bend radius on the metal plate in a second orientation that is opposed to the first orientation, and the magnitude of the first bend radius is equivalent to the magnitude of the second bend radius.
The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the present teachings when taken in connection with the accompanying drawings.
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.
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
The anti-crossbow station 14 is any suitable device that is capable of correcting a transverse curvature across a width of the strip of the metal sheet 25, i.e., a transverse crossbow, which develops as a result of leveling. The anti-coilset station 16 may be any suitable device that is capable of correcting a coilset of the metal sheet 25.
The leveling station 20 of the leveler 10 is advantageously configured to level a metal plate. The metal plate may be fabricated from metal material, including, but not limited to steel. The steel may be a high-strength steel, high-strength low alloy steel (HSLA), and the like. However, the leveler 10 is not limited to leveling metal plate that is fabricated from a metal material that includes steel. Further, the leveler 10 is not limited to leveling metal plate that is high-strength. The metal plate, e.g., the metal sheet 25 described herein, may be leveled by the leveling station 20 of the leveler 20 by bending the metal sheet 25 up and down as the metal sheet 25 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 subjects both sides of the metal sheet 25 to bending stress beyond elastic limits to effect leveling via plastification. The leveling station 20 preferably includes a frame 24 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. The equal quantity of two upper rollers 30, 35, and two lower rollers 40, 45 provide a balance in the plastification between both sides of the metal sheet 25. 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, such as with a freewheel device. As such, each upper roller 30, 35 and each lower roller 40, 45 is a freewheel device. The freewheel device may be a clutch or bearing that allows the respective upper roller 30, 35 and lower roller 40, 45 to turn freely about the respective axis of rotation 31, 36, 41, 46.
With reference to
Notable, the bending stresses, and thus the plastification of the metal sheet 25, substantially results from the unidirectional draw force F, applied by the draw device 18, relative to the longitudinal direction 13, and is not the result of stress applied to the metal sheet 25 by a bi-directional force, relative to the longitudinal direction 13, as would be done in conventional tension leveling.
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 a cylindrical outer peripheral surface 33 surrounding the axis of rotation 31 to 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.
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 a cylindrical outer peripheral surface 43 surrounding the axis of rotation 41 to 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.
The upper rollers 30, 35 and the lower rollers 40, 45 are in alternating relation to one another, such that 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. The 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 substantially equal in length.
Referring again to
The leveling station 20 is configured such that the longitudinal spacings 47, 48 and 49, the plunge depth 54, 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 bends about a portion of the outer peripheral surfaces 33, 43 of the upper rollers 30, 35 and the lower rollers 40, 45. The metal plate 25 is preferably subjected to plastic deformation when it bends about a portion of 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 54 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 54 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 substantially equivalent to the magnitude of the second bend radius 64.
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 subject a first outer area of the metal plate 25, located on a first surface thereof, to a bending stress, and subject a second outer area of the metal plate 25, located on a second, opposite surface thereof, to a bending stress.
When a relatively smaller force, e.g., a force less than the yield strength of a material, is applied to the material, the material deforms elastically, with the deformation being linearly proportional to the applied force, such that the elastic deformation is reversible, e.g., the material does not permanently change shape. The relationship between elastic deformation and applied stresses defines the materials' 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 is about one divided by ten million psi (1/10E6 psi). 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.
With reference to
Referring now to
A bend radius can be defined for a metal sheet, in relation to various factors, as follows:
Rs=E*T/k*Ys [1]
wherein:
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 subjected, across its entire cross-sectional area, to stress that is greater than its elastic limit has a 100% plastification.
With continued reference to
As the yield strength of the material being leveled increases, in order to achieve the desired level of plastification, a larger plunge depth 54 is required in order to impart a larger bend radius. As such, as the yield strength of the material being leveled increases, the required draw force F increases at a linear rate in order to achieve the desired magnitude of plastification. As such, by way of a non-limiting example, the linear rate for the first metal 111, i.e., A36, is about a 5:1. However, as the thickness of the metal sheet 25 increases, in order to achieve the desired magnitude of plastification, a smaller plunge depth 54 is required. As such, thinner gauge steel requires a greater increase in plunge depth 54, as the yield strengths increase, as compared to thicker gauges. Likewise, this requires that a roller with a smaller roll diameter, as the yield strengths increase for thin gauge steel.
With continuing reference to
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 stretched. 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. Likewise, as the metal sheet 200 proceeds through the serpentine path 28, the metal sheet 200 bends in the opposite direction, and that same portion of the cross-sectional area of the metal sheet 200 that was subject to be plastically compressed, becomes plastically stretched. The neutral portion 205 is only subjected to elastic bending. The inner portion 204 and the outer portion 207 each define the magnitude of plastification of the metal sheet 200, which may be any desired percentage, up to the order of magnitude of 50%, as shown. As such, any desired plastification across the entire metal sheet 200, in the order of magnitude of up to nearly 100%, may be achieved. It would be understood that, at plastification approaching 100%, the neutral portion 205 is negligible, e.g., is substantially non-existent.
The metal sheet 300 includes areas of stress deformation 322 and an area of bending 324 as the metal sheet 300 is drawn across the roller 310 and is subject to bending about a portion of 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.
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 each be any desired percentage, up to the order of magnitude of 50% for the bending radius 320. As such, any desired plastification across the entire metal sheet 300, in the order of magnitude of up to 100%, may be achieved.
As such, bending is achieved by controlling the plunge depth 54 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
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 54 of 1.25 inches to achieve a bend radius of less than 0.875 inches for a steel sheet that is 0.80 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%, while requiring the draw force F of approximately 70,000 pounds to be applied by the draw device 18. Overall, the bend radius is greater than or equal to the roller radius, where thinner gauge metal sheets require a higher bend radius, which leads to smaller roller radius. It should be appreciated that this concept applies to steel and other metal alloys of any magnitude of yield strength. Further, the combination of the plunge depth 54, the radius of the upper rollers 30, 35 and the lower rollers 40, 45, the longitudinal spacing, and the draw force F imparted by the draw device 18, allows greater than 90% plastification to be achieved using a leveling station 20 including only, i.e., not more than, two upper rollers 30, 35 and two lower rollers 40, 45. Further, the combination of the plunge depth 54, the radius of the upper rollers 30, 35 and the lower rollers 40, 45, the longitudinal spacing, and the draw force F imparted by the draw device 18 may be configured to allow the desired amount of plastification, without the addition of heat to the metal sheet.
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.
