Enson.Studio.: RollForming

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20221224

20221224-Merry Christmas

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#Update : 2022-12-24
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#Keywords: Roll Forming, ColdRollForming, RollFlower, COPRA, MerryChristmas, .
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聖誕節快樂，輥朵花立棵樹！

Merry Christmas.

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20200606

Roll Flower Design Practice - CN109351803B

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# Update: 2020-06-06
# Keywords: Roll forming, Roll flower, ... .
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# REF = 張堯,盛珍劍,阮建剛, 2020-0512, CN109351803B-P形鋼管的成型方法, 武漢鋼鐵江北集團冷彎型鋼有限公司.

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# Image :

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Roll Flower Design Practice - CN101954395B

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# Update: 2020-06-06
# Keywords: Roll forming, Roll flower, ... .
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# REF = CN101954395B-S型角連續輥式冷彎成形方法.

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# Image :

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20200307

Roll Forming Simulation of CN103394561B

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# Update = 2020-0308.
# Author : Enson, Yu.
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# Keywords: Roll Forming, Roll Flower, Simulation, ... .
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This study was referred to the China patent [CN103394561B].

Base on the claim figure, a 11 stages roll forming process was presented for designing the roll flower pattern.

The roll flower and rollers were designed by using COPRA, and simulated by using SIMUFACT.

# Roll flower :

# Roll Forming Simulation :

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# REF :

[1]CN103394561B, 一種確定板帶材冷彎成型各道次彎曲角度的方法.

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20190603

保桿內樑拉彎成形技術

(Stretch Bending Method for Bumper Beam)
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# Date: 2019-06-03.
# Author: Enson, C-H, Yu, Ph.D.
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# Keywords: Bumper beam, Roll forming, Stretch bending, ... .
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# 保桿內樑之常見做法：

將平鈑經輥軋成形(roll forming)與銲接接合後製造平直之管件，
再透過線上輥彎 (roll bending)或離線之拉彎成形(stretch bending)製造具有曲率之保桿內樑。

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# 離線拉彎成形：

利用夾頭夾持保桿內樑兩端後，旋轉拉張保桿，透過可更換圓弧尺寸的圓弧沖頭來改變拉張成形後的曲率 [KR101334061B1]：

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# 輥軋切斷後直接拉彎成形：

保桿內樑經連續輥軋成形平直內樑，經切斷後，直接夾持進行拉彎成形 [KR101241762B1] 。

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# VIDEO:

[] Stretch Bending Machine, Youtube, https://www.youtube.com/watch?v=jbdLWmNAySw

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# REFERENCE

[] 2011, Stretch bending device, KR101334061B1.

[] 2010, Roll forming system and roll forming method, KR101241762B1.

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20190307

連續輥軋相關論文 (Reference of Roll-Forming)

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Keywords: Paper, Reference, Roll forming, ... .

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[] Su, C. J., Yang, L. Y., Lou, S. M., Wang, Q., & Wang, R. (2019). Research on roll forming process based on five-boundary condition forming angle distribution function. The International Journal of Advanced Manufacturing Technology, 1-13. https://link.springer.com/article/10.1007/s00170-019-03377-y

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20181203

製管成形 (Tube Roll Forming)

Keywords: Tubing, Roll forming, Down-hill forming, ... .
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Flowers and strain distribution of U-O forming and Down-Hill forming.

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REFERENCE

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20181011

Roll Forming of Scaffolding Board

Keywords: Roll forming, Youtube, ... ...................................................

VIDEO:

[] LMS SCAFFOLDING WALKING BOARD ROLL FORMING PRODUCTION LINE, Youtube, https://youtu.be/TKpIccKDOuI

[] Scaffold Roll Forming Machine, Youtube, https://youtu.be/Rk6MmaF_iG0

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20180922

關於重構成形技術 (About Reconfiguration Forming)

Keywords: Multi-point forming, Sheet metal forming, Multi-punch forming, Reconfiguration forming, ... .

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為了搜尋柔性輥軋成形技術 ( Flexible roll forming)，找到了 Flexible Reconfiguration Roll Forming, 當初只視為某個創新的漸進式成形技術 (incremental forming)；直到看到其商品化新聞，才好好地搜尋了相關的專利和論文。

從目前的專利和論文資料來看，重構成形技術 (Reconfiguration forming) 大多利用油壓系統驅動多軸(沖頭)運動成形，適用於三維曲面大鈑件成形；商品化機械有 SKWB-2500 船舶三維數控彎鈑機。

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REFERENCE

SKWB-2500船舶三維數控彎板機, BAIKE, http://goo.gl/bKa0Ow

世界首台！複雜曲面船板自動加工設備成功應用, Read01, 20160226, https://goo.gl/HsqLAT

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Reconfiguration Forming

E.G. Haas, R.C. Schwarz,J.M. Papazian (2003) Single-die modularized, reconfigurable honeycomb core forming tool, US, 6578399,Northrop Grumman Corporation.

向祖權, 張燦勇, 李培勇, 李繼先, 焦和桐, 王呈方, 勇胡, 范正勇, 茅雲生, 萍袁,馬軍偉 (2009) 方形壓頭可調活絡模具板材曲面成形裝置, CN, 201361652,泰安市碩力液壓設備廠,武漢理工大學.

張燦勇, 焦和桐, 王呈方,勇胡 (2010) 非對壓多點板材成形裝置, CN, 101670392,武漢理工大學.

向祖權, 張燦勇, 李培勇, 李繼先, 焦和桐, 王呈方, 胡勇, 范正勇, 茅雲生, 袁萍,馬軍偉 (2011) 方形壓頭可調活絡模具板材曲面成形裝置, CN, 101549377,泰安市碩力液壓設備廠,武漢理工大學.

於忠奇, 王皓, 來新民, 林忠欽,孔慶帥 (2015) 三維曲面構件加工的多點柔性滾壓成形方法, CN, 103111499,上海交通大學.

馮朋曉, 李明哲, 胡志清, 隋振, 韓奇鋼,龔學平 (2011) 三維曲面輥壓成型裝置, CN, 102151732,吉林大學.

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Flexible Reconfiguration Roll Forming (FRRF)

Takashi Ishikawa, Ken-ichiro Mori, Daming Wang, Mingzhe Li,Zhongyi Cai (2014) Investigation on Forming Precision of Flexible Rolling Process for Three-dimensional Surface Parts of Different Sheet Materials, Procedia Engineering, Vol.81, pp.227-232.

Jun-Seok Yoon, So-Eun Son, Woo-Jin Song, Jeong Kim,Beom-Soo Kang (2014) Study on flexibly-reconfigurable roll forming process for multi-curved surface of sheet metal, International Journal of Precision Engineering and Manufacturing, Vol.15, pp.1069-1074.

Pan Liu, Tae-Wan Ku,Beom-Soo Kang (2015) Shape error prediction and compensation of three-dimensional surface in flexibly-reconfigurable roll forming, Journal of Mechanical Science and Technology, Vol.29, pp.4387-4397.

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20180612

旋轉沖孔 (Rotary Punching)

Keywords: Roll forming, Rotary punching, Roller design, ... .
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Google search = https://tinyurl.com/GSearch-RotPunch

透過輥輪連續沖孔。

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VIDEO:

[] Baust Rotationsstanze 3D - Rotary Punching 3D, YOUTUBE, https://youtu.be/p4BNOWGcAq0

[] BAUST Businessclip, dt , Neufassung 101209, Youtube, https://youtu.be/ijehcDU5LLM

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20180427

API 鋼管

Kwyeords: API, Tube, Pipe, ... .
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API 為美國石油學會之縮寫 (american petroleum institute, API) [WIKI]。

[] 相關 API 鋼管之 Google 新聞：https://tinyurl.com/API-NEWS

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Forming Method / 成形方法：
[] 製管輥軋成形 ( tube roll forming ) [ES]
[] 籠 / 排輥成形 ( cage roll forming ) [ES]

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台灣業者：

[] 中鴻( 2014 )、高興昌( 2008 )、燁輝( 2023 )、天聲。

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設備製造業者：

[] JP. Kusakabe, 日下部電機株式會社 [ http://www.kusakabe.com ]
[] JP. NAKATA, 中田製作所 [http://nakata-mfg.com]

相關軟體業者：

[] dataM COPRA RF FEA：輥花圖設計、輥輪設計、管車設計、CAE 分析 [http://www.datam.de] .

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REFERENCE

[] API, WIKI, https://tinyurl.com/API-WIKI-CHI

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關於籠成形技術 (Cage Roll Forming)

Keywords: Roll forming, Cage roll forming, Roller, ... .
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籠成形技術亦可稱作排輥成形技術，可用一套輥輪製造多種管徑鋼管，
知名的鋼管設備商，都有其專利，如：

[] 日本 KUSAKABE 的通用成形技術 (universal forming) [KUSAKABE]
[] 日本 NAKATA 的 FFX Mill (flexible forming mill) [NAKATA]
[] 德國 SEUTHE 的 CTA (central tool adjustment) [SEUTHE]

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機架設計

內輥設計 (internal roller) [US8464569]：

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REFERENCE

Universal forming, KUSAKABE, http://www.kusakabe.com/eng/forming/UniversalFormingMillEng.htm
FFX Mill, NAKATA, http://nakata-mfg.com/product/mill_ffx.html
CTA, SEUTHE, http://www.seuthe.com/en/se_productcategory/view/5749563331706880/Anlagen+mit+Cage+Forming+CTA®-Technologie
[] 任強 , 唐鼎 , 李大永 , 蔣勁茂 (2012) 直縫焊管排輥成形機組的工藝優化方法, CN, 102500640, 上海交通大學 , 無錫凱博易機電科技有限公司.
[] B. Heimann,J. Kamps (2013) Internal roller tool for bending a strip into a tube, US, 8464569,Sms Meer Gmbh.

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20171226

COPRA-RESTART

Keywords : COPRA RF FEA, Roll forming, Roller, Flower, CAE, FEA, ... .
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COPRA 是專業的連續輥軋設計與分析軟體，在 AutoCAD 介面中，
以 COPRA RF 進行花圖設計與輥輪設計，再轉檔到 COPRA FEA 進行成形分析。

若將輥軋成形視為多道次成形，其中某一道次出現問題了，
回過頭來修改輥輪和花圖，然後再從頭跑一次分析的話，那就前功盡棄太浪費時間了，
幸好 COPRA 提供了 RESTART 的功能，在完成修改輥輪(或鈑料)後，
將新輥輪與沒問題的分析道次結合，然後再繼續進行 CAE 求解。

以下圖之專利為例 (CN101954395B, S形拐角樁連續輥式冷彎成形方法)，

10道次輥軋成形，在第8站因為輥輪設計問題，導致鈑料無法進入成形區而形成疊料，
修改輥輪改以上輥壓料方式收納鈑料，在更新CAE模型後，接續第7站之分析結果，
即可快速完成分析，可看到此次修改能正確地成形鈑料到正確的位置。

YOUTUBE [https://youtu.be/G4JgMZvEer4]

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REFERENCE

[] CN101954395B, S形拐角樁連續輥式冷彎成形方法.
[] COPRA 2017, FEA RF Workbook.
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20171225

COPRA-RF-Merry Xmas

Keywords : Roll forming, roll flower, COPRA RF, ... .
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Merry Xmas，應景一下，玩玩 COPRA RF：

1. 創建斷面（section）

2. 以表單（spreadsheet）進行輥花圖（roll flower）展開。

Youtube [https://youtu.be/6JphW1TIkO0] :

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20171223

U 型樑連續輥軋成形分析

Keywords : U beam, Roll forming, COPRA RF/FEA, Simulation
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1. 6站式輥花圖與輥輪設計 (COPRA RF)

2. 1/2對稱模型之連續輥軋成形分析 (COPRA FEA / MSC.MARC)

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20171014

輥彎成形 (Roll Bending)

Keywords : Roll forming, Roll bending, Curving, Sheet metal ... .
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透過調整輥輪位置，並進行彈回補償，使鈑件形成特定尺寸之圓弧造型。

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Applications:

[] Roof panel [YT] .

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Machines:

[] RBM system : Demo [YT].

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REFERENCE.

[] Curving machine for standing seam roof panel, Youtube, https://youtu.be/IuKjK94tzMM
[] Schlebach RBM 25.38 Metal Curving Machine, YOUTUBE, https://youtu.be/R_oqn7oeSnY

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20170918

製管成形 (Manufacturing of Tubes and Pipes)

Keywords: Bending, Cage forming, Pipe, Roll forming, Stamping, Tube, ... .

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UOE 成形法 (Uing and Oing) ：

以沖壓方式，逐次將鈑材加壓成U型後，在加壓端部至近似圓形，再加以焊接成圓管，多用於大管徑鋼管，各道次斷面示意圖如下圖 [US4590781]，立體圖如 [US4971239] 所示。

UOE video:

[] Corus Tubes UOE video, YOUTUBE, https://youtu.be/Akk7YWUUp_Q

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相關製管車專利

[] Y. Kusakabe, K. Omura,H. Mori (2002) Roller mount with three-axis freedom, US, 6351978,Kusakabe Electric & Machinery Co.

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REFERENCE.

REF. UOE.

[] T. Toyooka (1986) Method for forming an electric resistance welded steel pipe, US, 4590781,Kawasaki Steel Corporation.
[] T. Tyler, W.A. Muller, G.A. Hart,M.G. Grabowski (1990) Method and apparatus for making welded tapered tubes, US, 4971239,Ameron, Inc.
[] Corus Tubes UOE video, YOUTUBE, https://youtu.be/Akk7YWUUp_Q

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20170720

關於連續輥軋 (About Roll Forming)

Keywords: Roll forming, ... .

連續輥軋(roll forming)是靠著一連串的輥輪將金屬鈑金逐步折彎成所需之斷面輪廓，屬 2D 漸進式成形，廣泛用於生產滑軌 (slide)、導軌 (rail)等結構件；發展至 2.5D 成形是輔以適當的輥彎輪，可改變產品曲率，形成具有相同斷面卻有曲率變化之產品，如汽車用保桿內樑(bumper beam)；而透過伺服馬達控制輥輪之運動路徑，將成為 3D 柔性輥軋成形技術 (3D flexible roll forming)，是極具發展潛力之鈑金成形技術。

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產品及公司：

川湖 (2059) = 滑軌、導軌
南俊 (6584) = 滑軌、導軌
青鋼 (8930) = 輕鋼架
中鴻 (2014) = 碳鋼管

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應用：

熱交換器微流道：以 22道次連續輥軋 (有縫管) 取代擠製成形 (無縫管) [Zou,2016]。

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工具

輥花圖設計 = datam COPRA RF、UBECO PROFIL
電腦輔助成形分析 = datam COPRA FEA、LS-DYNA、MSC.MARC

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REFERENCE

川湖科技股份有限公司, https://www.kingslide.com/
南俊國際股份有限公司, http://www.repon.com.tw/
青鋼金屬建材股份有限公司, http://www.ckm.com.tw/
中鴻鋼鐵股份有限公司, http://www.chsteel.com.tw/

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REF.PAPERS

Tianxia Zou, Ning Zhou, Yinghong Peng, Ding Tang and Dayong Li (2016) Numerical Simulation of the Roll Forming Process of Aluminum Folded Micro-channel Tube, Journal of Physics: Conference Series, Vol. 734, https://goo.gl/07IHuq

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REF. 滑(導)軌

靠滑軌進軍資訊業的奇蹟, BNext, 20050501, https://goo.gl/xRWRUw
川湖築起上千個專利高牆，讓世界看到台灣軟實力, Technews, 20160821, https://goo.gl/G1ceV3
南俊靠一條導軌訂單接不完,比川湖更老牌,從辦公家具搶進雲端商機, WEALTH, 20170109, https://goo.gl/LZdzTJ

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20170603

關於三維柔性輥軋 (About 3D Flexible Roll Forming)

關於三維柔性輥軋 (3D Flexible Roll Forming)

Keywords : 3D Flexible roll forming, DATAM, ORTIC, .

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三維柔性輥軋，可稱為 3D roll forming 或 Flexible roll forming.

具代表性之公司有 DATAM、ORTIC。
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DATAM，產品有：

COPRA RF FEA

3D Roll Forming Center [Maschinenmarkt]。

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ORTIC，產品有：

Monro 3d Roll Former
Polygon 3d Roll Former
Super Flexible 3d Roll Former

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POSCO：

POSCO Multi directional Roll Forming, PosRollForm [WEB].
POSCO Product Application Center [WEB]

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大學研究團隊：

Deakin University, Australia, https://blogs.deakin.edu.au/roll-forming/
北方工業大學, 輥彎成形團隊, China.

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應用柔性輥軋製造之產品有：

B柱補強鈑(B-Pillar reinforcing plate) [CJME,2016]

卡車門檻 (side sill) [PE,2017]。

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VIDEO

DATAM

Making Roll Formed Profiles with Discontinuous Cross Sections - 1

Making Roll Formed Profiles with Discontinuous Cross Sections - 2

DATAM-3D Rollforming Center

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ORTIC :

Ortic 3D Process - From idea to prototyping

Ortic Group - Advanced Roll Forming

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REFERENCE

DATAM, http://www.datam.de/

ORTIC, http://www.ortic.se/

Walzprofilieranlage bietet Vielfalt auf kleinem Raum, Maschinenmarkt, 20170306, https://goo.gl/jduWEn

REF. POSCO

PosRollForm (GSAS Flexible Roll Forming), https://goo.gl/IuWqSa
POSCO Product Application Center, http://www.poscopac.com/eng/
Processed Products, POSCO, http://www.poscopac.com/eng/sub02/04.php

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REF. Papers

Y. Yan, H. B. Wang, Q. Li,Y. Z. Guan (2016) Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification, Chinese Journal of Mechanical Engineering, Vol.29, pp.342-350. https://goo.gl/Hm6J8N
Dongun Kim, MyungHwan Cha, Yeon Sik Kang (2017) Development of the Bus Frame by Flexible Roll Forming, Procedia Engineering, Vol.183, pp.11-16. https://goo.gl/l5tLSs
Young Yun Woo, Sang Wook Han, Tae Woo Hwang, Ji Yeong Park, Young Hoon Moon (2018) Characterization of the longitudinal bow during flexible roll forming of steel sheets, Journal of Materials Processing Technology, Vol.252, pp.782-794.

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REF. Videos

Videos of DATAM

Making Roll Formed Profiles with Discontinuous Cross Sections - 1, Youtube, https://youtu.be/Muu3KC-mCLk

Making Roll Formed Profiles with Discontinuous Cross Sections - 2, Youtube, https://youtu.be/LAeGrKpR18Q

3D Rollforming Center, Youtube, https://youtu.be/-ExYY8LfU9A

Videos of ORTIC

Ortic 3D Process - From idea to prototyping, Youtube, https://youtu.be/g4j2ChaR-z0

Ortic Group - Advanced Roll Forming, Youtube, https://youtu.be/L6MIIeztaQk

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20160919

PROFIL - 保桿內樑輥軋工法設計

以 UBECO PROFIL 建立保桿內樑之輥花圖、輪廓應力分析及輥輪圖。

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Reference.

[1] US-5395036, Method of roll-forming an end automotive bumper.
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Youtube.

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Using UBECO PROFIL to design the flowers and rollers of an automotive bumper beam.

訂閱：文章 (Atom)

20221224

20221224-Merry Christmas

20200606

Roll Flower Design Practice - CN109351803B

Roll Flower Design Practice - CN101954395B

20200307

Roll Forming Simulation of CN103394561B

20190603

保桿內樑拉彎成形技術

20190307

連續輥軋相關論文 (Reference of Roll-Forming)

20181203

製管成形 (Tube Roll Forming)

20181011

Roll Forming of Scaffolding Board

20180922

關於重構成形技術 (About Reconfiguration Forming)

REFERENCE

Reconfiguration Forming

Flexible Reconfiguration Roll Forming (FRRF)

20180612

旋轉沖孔 (Rotary Punching)

20180427

API 鋼管

關於籠成形技術 (Cage Roll Forming)

機架設計

REFERENCE

20171226

COPRA-RESTART

20171225

COPRA-RF-Merry Xmas

20171223

U 型樑連續輥軋成形分析

20171014

輥彎成形 (Roll Bending)

20170918

製管成形 (Manufacturing of Tubes and Pipes)

REFERENCE.

20170720

關於連續輥軋 (About Roll Forming)

相關成形技術：

產品及公司：

應用：

工具

REFERENCE

REF.PAPERS

REF. 滑(導)軌

20170603

關於三維柔性輥軋 (3D Flexible Roll Forming)

VIDEO

REFERENCE

REF. POSCO

REF. Papers

REF. Videos

Videos of DATAM

Videos of ORTIC

20160919

PROFIL - 保桿內樑輥軋工法設計

Reference.

Youtube.