Systems, methods and devices for 3d rolling of multi-gauge parts

Abstract

Disclosed are metalworking rollers for fabricating multi-gauge sheet metal parts, methods for making and methods for using such rollers, and rolling mill machines employing variable-radius metalworking rollers for fabricating multi-gauge metal components. A metalworking roller for a rolling mill machine is disclosed. The metalworking roller includes a cylindrical roller body that rotatably and drivingly connects to the rolling mill machine. An outer diameter surface spanning around the roller body circumference includes an outermost peak region and an innermost valley region recessed radially inward from the outermost peak region and elongated circumferentially around the roller body. During operation of the rolling mill machine, the outermost and innermost regions of the roller body's outer diameter surface sequentially press against and thereby modify the gauge of a metal workpiece. Each region has a respective transverse width and circumferential length extending across and around the longitudinal length and circumference, respectively, of the roller body.

What is claimed: 
     
         1 . A metalworking roller for a rolling mill machine operable to modify a gauge of a metal workpiece, the rolling mill machine including a drive mechanism and a roll stand, the metalworking roller comprising:
 a cylindrical roller body configured to rotatably attach to the roll stand and drivingly connect to the drive mechanism, the roller body including an outer diameter surface spanning continuously around the circumference of the roller body, the outer diameter surface including an outermost peak region and an innermost valley region recessed radially inward from the outermost peak region and elongated circumferentially around the roller body,   wherein the outermost peak region and the innermost valley region are configured to sequentially press against and thereby modify the gauge of the metal workpiece.   
     
     
         2 . The metalworking roller of  claim 1 , wherein the innermost valley region has a first transverse width extending at least 30% of a longitudinal length of the cylindrical roller body. 
     
     
         3 . The metalworking roller of  claim 2 , wherein the innermost valley region has a first circumferential length extending at least 20% around the circumference of the cylindrical roller body. 
     
     
         4 . The metalworking roller of  claim 2 , wherein the innermost valley region has a first surface area and a first radial thickness constant along a length and a width of the first surface area. 
     
     
         5 . The metalworking roller of  claim 1 , wherein the outermost peak region has a second transverse width extending the entirety of a longitudinal length of the cylindrical roller body. 
     
     
         6 . The metalworking roller of  claim 5 , wherein the outermost peak region has a second circumferential length extending continuously around the entirety of the circumference of the cylindrical roller body. 
     
     
         7 . The metalworking roller of  claim 7 , wherein the outermost peak region has a second surface area and a second radial thickness constant along a length and a width of the second surface area. 
     
     
         8 . The metalworking roller of  claim 1 , wherein the outer diameter surface further includes an intermediate plain region recessed radially inward from the outermost peak region and elongated circumferentially around the roller body, wherein the innermost valley region is recessed radially inward from the intermediate plain region. 
     
     
         9 . The metalworking roller of  claim 8 , wherein the intermediate plain region has a third transverse width extending at least 50% of a longitudinal length of the cylindrical roller body. 
     
     
         10 . The metalworking roller of  claim 8 , wherein the intermediate plain region has a third circumferential length extending at least 40% around the circumference of the cylindrical roller body. 
     
     
         11 . The metalworking roller of  claim 8 , wherein the intermediate plain region has a third surface area and a third radial thickness constant along a length and a width of the third surface area. 
     
     
         12 . The metalworking roller of  claim 1 , wherein the outer diameter surface further includes descending and ascending stepped segments at leading and trailing edges, respectively, of the innermost valley region, the descending and ascending stepped segments interconnecting the innermost valley region with the outermost peak region. 
     
     
         13 . The metalworking roller of  claim 12 , wherein the descending and ascending stepped segments each comprises round-chamfered edges at intersection points with the innermost valley region and the outermost peak region. 
     
     
         14 . A rolling mill machine for changing a gauge of a sheet metal workpiece, the rolling mill machine comprising:
 a roll stand;   a drive mechanism operatively connected to the roll stand;   a subjacent roller rotatably mounted to the roll stand; and   a metalworking roller drivingly connected to the drive mechanism and rotatably mounted to the roll stand juxtaposed with the subjacent roller, the metalworking roller including a cylindrical roller body with an outer diameter surface spanning continuously around the circumference of the roller body, the outer diameter surface including an outermost peak region and an innermost valley region recessed radially inward from the outermost peak region, the outermost peak region and innermost valley region each having a respective surface area and a respective radial thickness constant along a length and a width of the respective surface area,   wherein the outermost peak region and the innermost valley region are configured to sequentially press against and thereby reduce the gauge of the sheet metal workpiece to include first and second distinct gauges.   
     
     
         15 . A method of changing a gauge of a metal workpiece via a rolling mill machine with a metalworking roller rotatably mounted on a roll stand and drivingly connected to a drive mechanism of the rolling mill machine, the method comprising:
 feeding the metal workpiece into engagement with the metalworking roller, the metalworking roller including a cylindrical roller body with an outer diameter surface spanning continuously around the circumference of the roller body, the outer diameter surface including an outermost peak region and an innermost valley region recessed radially inward from the outermost peak region and elongated circumferentially around the roller body; and   rotating the metalworking roller via the drive mechanism such that the outermost peak region and the innermost valley region sequentially press against and thereby modify the gauge of the metal workpiece.   
     
     
         16 . The method of  claim 15 , wherein the innermost valley region has a first transverse width and a first circumferential length, the first transverse width extending at least 30% of a longitudinal length of the cylindrical roller body, and the first circumferential length extending at least 20% around the circumference of the cylindrical roller body. 
     
     
         17 . The method of  claim 15 , wherein the innermost valley region has a first surface area and a first radial thickness constant along a length and a width of the first surface area. 
     
     
         18 . The method of  claim 15 , wherein the outermost peak region has a second transverse width and a second circumferential length, the second transverse width extending the entirety of a longitudinal length of the cylindrical roller body, and the second circumferential length extending around the entirety of the circumference of the cylindrical roller body. 
     
     
         19 . The method of  claim 15 , wherein the outermost peak region has a second surface area and a second radial thickness constant along a length and a width of the second surface area. 
     
     
         20 . The method of  claim 15 , wherein the outer diameter surface further includes an intermediate plain region recessed radially inward from the outermost peak region and elongated circumferentially around the roller body, wherein the innermost valley region is recessed radially inward from the intermediate plain region.