The present disclosure relates to rolled or extruded metal and sheet metal or metal plate processing. More particularly, the present invention relates to a method and apparatus for stretching extruded or sheet metal using a stretcher machine.
A wide variety of manufactured goods contain processed sheet metal. For example, aircraft, automobiles, file cabinets and household appliances, to name only a few, contain sheet metal. The sheet metal is typically purchased directly from steel mills and/or steel service centers, but may be passed through intermediate processors (sometimes referred to as “toll” processors) before it is received by an original equipment manufacturer.
Various methods exist for flattening or stretching sheet metal. Flatness of sheet metal is important because virtually all stamping and blanking operations require a substantially flat sheet. Also, in certain applications, such as in the aerospace industry, residual stress free material is critical. Good surface conditions are also important, especially in applications where the top and/or bottom surfaces of the metal sheet will be painted.
There are a number of common defects that effect sheet metal flatness. For example, when sheet metal is rolled into coil form for convenient storage and transportation, the strip tends to take on a coiled shape. This curvature is commonly referred to as “coil set.” Coil set occurs because the sheet metal has been bent past its yield point. More specifically, when sheet metal is coiled, the metal fibers near the inside surface of the curved sheet are compressed past their yield point, and the metal fibers near the outside surface of the curved sheet are stretched past their yield point. Another type of shape defect known as “edge wave” occurs if the edge portions of the sheet are no longer than the center portion of the sheet, resulting in undulations in one or both of the edge portions of the sheet. A similar type of shape defect known as “center buckle” results if the center portion of the sheet is longer than one or both of the edge portions, which results in bulging or undulating of the central portion of the sheet.
An existing method of flattening sheet metal is called “stretcher leveling.” A conventional C-frame stretcher leveler is shown schematically in
However, a problem with a conventional C-frame stretcher leveler is that it cannot be used with continuous strips of metal because the C-shaped grippers clamp at the opposed ends of a metal sheet, as shown in
U.S. Pat. No. 4,751,838, issued to Kenneth Voges, discloses an “in-line stretcher leveler.” The teachings of this patent are incorporated herein by reference. The basic components of conventional in-line stretcher leveler are shown schematically in
A problem with some existing stretchers is that the cam-style jaw has a profile such that the gripping angle changes depending on the thickness of the workpiece. This results in less efficient and unreliable gripping force across a variety of extrusion thicknesses or sizes. Also, the gripping force is disproportional to the stretching force. It is thus desirable to provide a stretcher for extrusions or plates or sheets which provide a uniform or constant gripping angle for various extrusion sizes or thickness and a gripping force which is proportional to the stretching force.
The disclosure relates to a stretching device. More particularly, it relates to an extrusion stretching device which provides a uniform or constant gripping angle and a gripping force to which is proportional to the stretching force on the extruded piece of sheet metal or a plate of metal.
The stretching device has opposite ends, a “head” stretcher and a “tail” stretcher which are used to pull an extrusion through the stretcher, wherein the “tail” has a cam-style jaw which holds the extrusion in place and is stationary, while the “head” has a cam-style jaw which grips and clamps down or the extrusion and moves to stretch the extrusion or pulls it through the device.
Each cam-style jaw has a geometry such that the gripping angle of the jaw is the same, regardless of the thickness of the cross section of the extrusion. In previous stretchers, the angle of the cam would change depending on the thickness of the workpiece, thus affecting the efficiency or effectiveness of the device.
Furthermore, the gripping force of the cam jaw which now results is proportional to the stretching force exerted on the workpiece. The gripping angle between the jaw and the workpiece or extension remains constant regardless of the thickness of the workpiece.
Thus, the harder the stretcher pulls on the workpiece, i.e., the larger the stretching force, the larger the gripping force. Thus, the gripping or wedging force is directly proportional to the stretching force.
In accordance with one aspect of the present disclosure, a stretching device has a housing; a first clamping member attached to a first portion of the housing; a second clamping member attached to a second portion of the housing; wherein the first clamping member comprises a movable pivot member such that an angle of contact between the first clamping member and a workpiece to be gripped remains constant regardless of the workpiece's thickness.
In accordance with another aspect of the present disclosure, a stretcher assembly, has a first stretcher having a first housing including a first clamping member and a second clamping member opposed to each other; and a second stretcher including a second housing having a third clamping member and a fourth clamping member opposed to each other; a workpiece support member interposed between the first stretcher and the second stretcher, wherein the first and third clamping members each has a movable pivot joint such that an angle of contact of the first and third clamping members with a workpiece to be gripped remains constant regardless of a thickness of the workpiece.
In accordance with another aspect of the disclosure, a method of stretching a workpiece includes: providing a first stretcher assembly; providing a second stretcher assembly; providing a support member between the first stretcher assembly and the second stretcher assembly; moving the first stretcher assembly into a desired location and securing the first stretcher assembly in the location; providing a pair of clamping members to the first and second stretcher assemblies; feeding a workpiece between the first and second stretch assemblies; clamping the workpiece between each pair of clamping members by moving each clamping member until the clamping members exert a gripping force on the workpiece; wherein the clamping members are configured such that an angle of gripping contact between the clamping members and the workpiece remain constant regardless of the thickness of the workpiece; and moving the second stretcher assembly away from said first stretcher assembly to exert a stretching force on the workpiece.
Yet another aspect of the disclosure is an extrusion stretcher which has optimized cam style jaws which provide a uniform, reliable gripping force across the full range of extrusion sizes. The stretcher effectively grips the piece and virtually eliminates any slippage.
Still another aspect of the disclosure is the extrusion stretcher has two ends; i.e., the head end or stretcher and the tail end or stretcher. The larger end, the tail, has a cam-style jaw which wedges on clamps down on the work piece and remains stationary. The smaller end, the head end, also has a cam-style jaw which wedges and clamps the workpiece but also pulls on the workpiece and stretches it.
Another aspect of the disclosure is the jaw has a geometric cam profile such that a gripping angle between the jaw and the workpiece is constant for various workpiece thicknesses.
Still another aspect of the disclosure is that the pivot point of the jaw moves up or down so that the angle of contact between the jaw and the workpiece remains constant regardless of the thickness of the workpiece.
Still another aspect of the disclosure is that the gripping or clamping force is proportional to the stretching force.
Another aspect of the disclosure is that the cam jaws exert a uniform, reliable gripping force on workpieces across a full range of workpiece thicknesses.
Still another aspect of the disclosure is that the jaw pre-grips the workpiece and virtually eliminates slippage.
Other aspects of the disclosure will become apparent upon a reading of the following description.
A method of flattening sheet metal using a stretcher is called “stretcher leveling.” A stretcher, in accordance with the present disclosure is shown in
The cam-style gripper or jaw assembly 14 securely grips one of the opposing ends of an extrusion or a sheet of metal to be stretched. The surface edges or portions 22 of the jaws that engage or grip the sheet metal to hold the sheet against movement during stretching are typically grooved, knurled or serrated (see
A coil strip of metal, such as steel or titanium, is positioned to run between the jaws. Where the distance between jaws of opposing stretcher assemblies is great, for example, 50 feet or more, the strip is supported by a plurality of rolls or other support means. A length of the workpiece to be stretched can range from several feet to over 100 feet in length.
The gripping surface of a jaw can be made of a material strong enough not to break down or tear away from the support surface under an applied force up to 350 tons. The gripping jaw surface must also have a coefficient of friction great enough to prevent slippage of the surface with respect to the workpiece being stretched during operation of the stretcher. Additionally, the gripping jaw should not damage the workpiece that it grips or stretches.
It has been found that it is desirable that the width of the jaw gripping surface be from about three inches in width. However, other widths are contemplated by the disclosure.
To prepare the stretchers for operation, a metal strip is withdrawn from a coil. Then with the clamping assemblies of the stretching machine in their raised positions, the strip is fed between the jaws through the space between the guide plates on the lower frame, and finally between the jaws of the upper jaw assembly. In other words, the strip is advanced along a path through the stretcher.
Specifically, referring again to
Referring now to
As seen in
An upper portion of housing 12 encloses the upper jaw assembly in the retracted or “up” position. An opening or gap 40 of about 16 inches is formed in the housing between the portion 31 of the housing enclosing the upper or top jaw assembly 14 and the bottom or lower jaw assembly 26.
A workpiece 70 is inserted into the tail assembly between the upper and lower jaw assemblies when the upper jaw assembly is in the retracted position (
Referring now to
The head stretcher assembly has a pair of hydraulic cylinders 52 attached to a bottom jaw assembly 54 including a substantially flat plate 55. A plurality of hydraulic cylinders 56 are attached to a plurality of upper cam-style jaws 58 which are arranged adjacent and parallel to each other. In the preferred embodiment, seven jaws 58 and cylinders 56 are shown, but other numbers of jaws can be used without departing from the of the disclosure. Both the bottom jaw assembly 54 and upper jaws 58 are mounted to a housing 60 between opposed side walls 61 and 63.
The bottom jaw is interposed between two jaw keepers or guide members 62, which in turn are used to extend the bottom jaw outwardly.
The head stretcher assembly 50 also has a cam-style jaw assembly which pivots between “up” and “down” positions into and out of the housing. The head assembly cam jaw extends downwardly which exerts a gripping force and wedges against the workpiece or extrusion and clamps it into place. The jaws in the tail assembly remain stationary and do not exert any stretching force on the workpiece. The jaws of the head assembly housing move away from the tail housing 10 in direction D (
Housing 60 encloses the upper jaw assembly in the retracted or “up” position between opposing side walls 61, 63. An opening 66 (
Workpiece 70 is inserted into the head assembly between the upper and lower jaw assemblies when the upper jaw assembly is in the retracted position (
The entire cross section of the metal sheet is typically stretched past its yield point (i.e., beyond its elastic limit) such that all internal residual stresses are eliminated from top to bottom and from side to side.
In typical operation, a strip is positioned between jaws which are hydraulically or pneumatically controlled. Once a firm contact is made with the strip, hydraulic cylinders actuate a pair of jaws to move in opposite direction from the other pair to elongate the strip between the jaw pairs. Once elongation has been achieved, jaw pairs are opened and the stretched portion of strip can be incrementally taken up on takeup coil and the next stretching operation can begin.
Referring now to
The cylinders move the clamping jaws for the respective housings downwardly, causing the opposed jaws to approach each other and clamp down and wedge against the strip. The number of clamping cylinders energized depends on the width of the workpiece or strip 70, since it is not desirable to apply the clamping force much beyond the edges of the strip. At each housing, the clamping force produced by the cylinders that are energized is distributed uniformly across the strip or workpiece. The clamping cylinders effect a tight grip across the strip at each set of clamping jaws, yet the jaws do not damage the surfaces of the strips.
The stretcher can include a feeding mechanism (not shown), including a plurality of powered rollers for pulling the sheet metal strip 70 through the stretcher assembly. The feeding mechanism can advance the sheet metal strip 70 through the stretcher assembly at precise increments.
With the clamping jaws in the up position, the sheet metal strip 70 is fed between the upper and lower gripping jaws. The clamping cylinders are energized on each of the housings to move the clamping mechanisms (jaws 32, 58) downwardly to bring the jaws 32, 58 into firm engagement with the top surface of the sheet metal strip 70. The upper gripping jaws or members approach the lower gripping members (lower jaws 26, 54) so that the sheet metal strip 70 is gripped firmly therebetween. With the strip tightly gripped between the upper and lower gripping members, a hydraulic stretching cylinder (not shown) is energized to exert a pulling force on a bracket 59 attached to the head to move the movable housing 60 of the head stretcher 50 away from the fixed housing 12 of the tail stretcher 10 in direction D (
The upper cam jaw 32, 58 used in both the tail stretcher and head stretcher is shown in
Specifically, the gripping angle (GA) of the cam-style jaw is shown in
Referring now to
Referring now to
The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
This application claims priority from Provisional Application No. 61/060,999, filed on Jun. 12, 2008.
Number | Name | Date | Kind |
---|---|---|---|
1903638 | Sykes | Apr 1933 | A |
3247565 | Griffin | Apr 1966 | A |
3349598 | Pollak | Oct 1967 | A |
4751838 | Voges | Jun 1988 | A |
4982593 | Holloway | Jan 1991 | A |
5077887 | Holloway | Jan 1992 | A |
5181411 | Holloway | Jan 1993 | A |
5491999 | Holloway | Feb 1996 | A |
6205830 | Voges | Mar 2001 | B1 |
6227027 | Holloway | May 2001 | B1 |
6612145 | Rohleder | Sep 2003 | B2 |
6732561 | Voges | May 2004 | B2 |
Number | Date | Country | |
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20090308127 A1 | Dec 2009 | US |
Number | Date | Country | |
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61060999 | Jun 2008 | US |