Continuous process of roll-forming stamped sheet

Abstract

An apparatus includes a press with dies configured to deform a strip of material by drawing material primarily from a width direction, a slitter set to cut the deformed strip to a uniform desired width dimension, and a roll-former with rolls configured to shape linear portions of the deformed and now uniform-width strip into a continuous beam. The apparatus further includes a welder for welding abutting edges of the sheet together to form a permanent tube, a sweep station for imparting a longitudinal shape to the continuous beam, and a cut-off for cutting the continuous beam into segments useful as vehicle bumper beams. A controller controls timing of various components. The beam segments are optimized in specific regions for local strength and minimized weight, and features can be incorporated into the beam segments such as coplanar mounting surfaces.

1 . An apparatus adapted to form a reinforcement beam comprising: 
 a press including dies configured to deform a flat strip of heated metal material into a deformed strip with a three-dimensional shape by drawing and moving material;    a cooling system associated with the press and configured to cool the heated metal material of the deformed strip; and    a roll-former downstream of the press and cooling system and having rolls configured to shape edge portions of the deformed strip into a continuous beam.    
   
   
       2 . The apparatus defined in  claim 1 , including stamping dies in the press having at least a portion of the cooling system therein.  
   
   
       3 . The apparatus defined in  claim 2 , including a slitter set to cut the deformed strip to a uniform width of desired constant dimension.  
   
   
       4 . The apparatus defined in  claim 2 , wherein the dies are configured to stretch and extrude the material in a lateral direction.  
   
   
       5 . The apparatus defined in  claim 1 , wherein the cooling system is connected to the dies.  
   
   
       6 . The apparatus defined in  claim 1 , wherein the rolls are configured and arranged to cause the opposing edge portions of the strip to abut.  
   
   
       7 . The apparatus defined in  claim 6 , including a welder configured to weld the opposing edge portions together to form the beam as a permanent continuous tube.  
   
   
       8 . The apparatus defined in  claim 7 , including a cut-off device for cutting the permanent continuous tube into beam segments.  
   
   
       9 . The apparatus defined in  claim 1 , including a controller for controlling the press, the roll-former, and the cooling system in a coordinated manner.  
   
   
       10 . The apparatus defined in  claim 1 , including a sweep station configured to impart a longitudinally curved shape to the beam.  
   
   
       11 . The apparatus defined in  claim 1 , wherein the dies are configured to form flat mounting surfaces.  
   
   
       12 . An apparatus adapted to form a reinforcement beam comprising: 
 a heater configured to heat steel material to a temperature of at least about 850° C.;    a press including dies configured to deform a continuous strip of hot steel material;    a cooling system associated with the press for quenching and hardening the hot steel material; and    a roll-former positioned in-line with the press and downstream of the cooling system and having rolls configured and arranged to receive the strip in the feed direction and shape edge portions of the deformed strip into a reinforcement beam.    
   
   
       13 . A method comprising steps of: 
 hot-stamping a sheet of heated steel material having a first tensile strength, including drawing and stretching the material;    quenching the stamped sheet to cause the material to have a higher tensile strength; and    roll-forming portions of the stamped sheet by use of a roll-forming mill into a beam.    
   
   
       14 . The method defined in  claim 13 , wherein the step of roll-forming is done along edge portions of the sheet generally outboard of a center portion of the sheet.  
   
   
       15 . The method defined in  claim 13 , wherein the material has a yield strength after quenching of at least about 1000 MPa.  
   
   
       16 . The method defined in  claim 13 , wherein the material has a tensile strength after quenching of at least about 1500 MPa.  
   
   
       17 . The method defined in  claim 13 , including abutting and then welding edges of the sheet together to form a permanent tube.  
   
   
       18 . The method defined in  claim 13 , including a step of sweeping the continuous beam into a longitudinal curvilinear shape.  
   
   
       19 . The method defined in  claim 18 , wherein the step of stamping includes forming mounting surfaces on the first strip portion, the mounting surfaces being configured to engage and be secured to vehicle frame rails.  
   
   
       20 . A method of forming a reinforcement beam comprising steps of: 
 providing a heater;    providing a press including forming dies at a location downstream of the heater and also a cooling system associated with the press;    providing a roll-former having rolls in-line and downstream of the press;    heating a strip of material;    operating the dies to deform the strip of material by drawing the hot material and thereafter quickly cooling the material; and    operating rolls of a roll-forming mill to receive the strip in a feed direction and shape edge portions of the deformed strip into a reinforcement beam.