Cold roll forming apparatus

Abstract

A cold roll forming mill for the manufacture of hollow flange seam welded beams from a single strip of metal comprises a forming station ( 1 ), a seam guide and welding station ( 2 ) and a shaping station ( 3 ). Either or both of the forming and shaping stations ( 1,3 ) comprise independently supported side engaging roll combinations ( 7,12 ) adapted, in use, to roll either or both of opposite sides of the strip. Adjacent transverse pairs of side engaging roll ( 7,12 ) combinations are selectively movable relative to each other in a transverse direction perpendicular to a direction of travel of said strip through said mill. At least some of the side engaging roll combinations ( 7,12 ) are driven. Drive rolls ( 6 ) spaced within the forming and shaping stations ( 1,3 ) engage the strip between opposite edges thereof.

1 . A cold roll forming mill for the manufacture of hollow flange seam welded beams from a single strip of metal, said mill comprising:
 a forming station;   a seam guide and welding station; and,   a shaping station;   wherein either or both of said forming station and said shaping station comprises independently supported side engaging roll combinations adapted, in use, to roll either or both of opposite sides of said strip, adjacent transverse pairs of said side engaging roll combinations being selectively movable relative to each other in a transverse direction perpendicular to a direction of travel of said strip through said mill, and all forming and shaping rolls of either or both of said forming station and said shaping station consist of said side engaging roll combinations; and   wherein each of said roll stand frames is independently and selectively movable transversely of a mill bed.   
   
   
       2 . A mill as claimed in  claim 1  wherein some or all of said side engaging roll combinations are idler rolls. 
   
   
       3 . A mill as claimed in  claim 1  wherein some or all of said side engaging roll combinations are drive rolls. 
   
   
       4 . A mill as claimed in  claim 1  wherein drive rolls, spaced within said forming station and spaced within said shaping station engage a central region of said strip between formed edge regions thereof. 
   
   
       5 . A mill as claimed in  claim 4  wherein some or all of said drive rolls engage said strip over a substantial portion thereof between formed edge regions of said strip. 
   
   
       6 . A mill as claimed in  claim 4  wherein some or all of said drive rolls engage said strip adjacent a central portion spaced from said formed edges. 
   
   
       7 . A mill as claimed in  claim 4  wherein some or all of said drive rolls engage said strip adjacent opposed formed edges thereof. 
   
   
       8 . A mill as claimed in  claim 1  wherein transverse pairs of side engaging roll combinations are mounted on respective roll stand frames. 
   
   
       9 . A mill as claimed in  claim 1  wherein transverse pairs of said side engaging roll combinations are movably mounted on a common roll stand frame. 
   
   
       10 . A mill as claimed in  claim 1  wherein at least one side engaging roll of a side engaging roll combination is rotatably mounted on an inclined axis lying in a transverse plane perpendicular to a direction of travel of a strip of metal through said side engaging roll combination. 
   
   
       11 . A method of cold roll forming a hollow flange member from a single strip of metal, said method comprising:
 driving a metal strip through a cold rolling mill by driven rolls engaging a planar central region of said strip;   forming a contour along at least one edge region of said strip by forming rolls;   continuously seam welding by an ERW process a free edge of said at least one edge region to a surface of said strip along a predetermined weld region to form a hollow flange; and,   shaping said hollow flange by shaping rolls to form a shaped hollow flange of desired cross-sectional configuration;   wherein said forming rolls and said shaping rolls consist of side engaging roll combinations each being independently and selectively movable relative to each other in a transverse direction perpendicular to a direction of travel of said strip through said mill.   
   
   
       12 . A method as claimed in  claim 11  wherein one or more of said forming rolls are driven to assist in driving said strip through said mill. 
   
   
       13 . A method as claimed in  claim 11  wherein one or more of said shaping rolls are driven. 
   
   
       14 . A method as claimed in  claim 11  wherein prior to continuous seam welding, said free edge is aligned linearly with a predetermined weld axis on said surface of said strip and said at least one free edge is guided through a predetermined linear trajectory along an incidence axis of a subsequent weld junction between said at least free one free edge and said surface wherein energy imparted to said hollow flange member is focussed by a proximity effect along said predetermined weld axis on said surface prior to fusing said at least one free edge thereto. 
   
   
       15 . A method as claimed in  claim 11  wherein said at least one free edge is aligned with said weld region by one or more seam rolls each having a circumferential shoulder providing an abutment for said at least one free edge. 
   
   
       16 . A method as claimed in  claim 15  wherein at least one free edge of said metal strip is urged into abutment with said circumferential shoulder by a contoured guide roll. 
   
   
       17 . A method as claimed in  claim 15  wherein said metal strip is supported centrally by opposed cylindrical roll surfaces adjacent said weld region as said at least one free edge is urged into abutment with said circumferential shoulder. 
   
   
       18 . A method as claimed in  claim 15  wherein at least one free edge is guided toward said closure region at a predetermined angle relative to strip surface by adjustably mounted seam rolls. 
   
   
       19 . A method as claimed in  claim 11  wherein said at least one free edge of said metal strip is guided through said predetermined trajectory by a contoured squeeze roll extending over said contoured surface of said metal strip between spaced substantially parallel contact faces of said contoured squeeze roll. 
   
   
       20 . A method as claimed in  claim 11  wherein weld energy is imparted to said free edge and said predetermined weld region by an electrical induction coil, said coil extending substantially around said metal strip in a plane substantially perpendicular to a longitudinal axis thereof.