U.S. patent number 3,678,720 [Application Number 05/063,408] was granted by the patent office on 1972-07-25 for roller leveler and method of leveling.
This patent grant is currently assigned to Sutton Engineering Company. Invention is credited to Ray A. Bland, Clyde W. Dickey.
United States Patent |
3,678,720 |
Dickey , et al. |
July 25, 1972 |
ROLLER LEVELER AND METHOD OF LEVELING
Abstract
In a roller leveler a roll is rotatably supported in a position
to be engaged by an elongated workpiece traveling through the
leveler. The roll has a hollow cylindrical body, inside of which
there are ferroelectric transducers close to its inner surface.
These transducers are driven electrically to vibrate the roll body
radially in all directions at ultrasonic frequencies to relieve
residual stresses in the workpiece passing across the roll.
Inventors: |
Dickey; Clyde W. (State
College, PA), Bland; Ray A. (Pittsburgh, PA) |
Assignee: |
Sutton Engineering Company
(Pittsburgh, PA)
|
Family
ID: |
22048994 |
Appl.
No.: |
05/063,408 |
Filed: |
August 13, 1970 |
Current U.S.
Class: |
72/160;
72/199 |
Current CPC
Class: |
B21D
1/02 (20130101); B21D 35/008 (20130101); F16C
13/00 (20130101) |
Current International
Class: |
F16C
13/00 (20060101); B21D 1/00 (20060101); B21D
1/02 (20060101); B21d 001/02 () |
Field of
Search: |
;72/160-165 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"Ultrasonics Research Promises Production Payoff," Machinery, Oct.
1967, pp. 95-97..
|
Primary Examiner: Mehr; Milton S.
Claims
We claim:
1. In a roller leveler, a framework, an ultrasonic roll, and means
rotatably supporting the roll in the framework in a position to be
engaged by an elongated workpiece passing through the leveler, said
roll comprising a hollow cylindrical roll body, a support inside
said hollow roll body and extending axially thereof, means rigidly
holding said support and spacing it from the inner surface of the
roll body, ferroelectric transducers inside said roll body
supported by said support close to but spaced from said inner
surface of the roll body, means sealing the opposite ends of the
roll body, a liquid filling all of the empty space between said
support and the encircling roll body, and electrical means for
driving the transducers to vibrate said roll body radially at
ultrasonic frequencies to cause the workpiece to become flat.
2. In a roller leveler according to claim 1, thrust rollers in said
framework engaging the opposite ends of said roll body to prevent
axial movement of the roll, and said roll-supporting means being
support rollers engaging the outer surface of the roll body at its
ends for preventing radial displacement of the roll.
3. In a roller leveler according to claim 1, said electrical means
including a transformer core section mounted in an end of said
hollow roll body, and a secondary winding carried by said core, the
leveler also including a transformer core section mounted in said
framework at said end of the roll, and a primary winding carried by
said last-mentioned core section, the two core sections being
axially aligned with a slight air gap between them.
4. In a roller leveler according to claim 3, one of said core
sections being rigidly mounted in said roll body, and the other
core section being rigidly mounted in said framework.
5. In a roller leveler according to claim 1, said support being
hollow and provided with an air chamber having a flexible wall, and
said support being provided with an opening outside said chamber
communicating with said wall, said liquid engaging said flexible
wall to compress air in said chamber when the liquid in said roll
body expands with heat.
6. In a roller leveler according to claim 1, idler rolls mounted in
said framework at opposite sides of said ultrasonic roll for
engaging the side of the workpiece opposite to the side engaging
said roll and means for adjusting the spacing between said idler
rolls to obtain longitudinal resonance in the workpiece.
7. In a roller leveler according to claim 6, backup rolls engaging
the ultrasonic roll at points diametrically opposite the ends of
the arc of said roll engageable by the workpiece.
8. In the method of roller leveling or straightening a
longitudinally moving elongated metal workpiece by reversely
bending it, the steps comprising directing the workpiece part way
around a hollow roll in engagement therewith throughout an arc of
not more than 90.degree., simultaneously returning the strip in the
opposite direction part way around the opposite side of said roll
in engagement therewith, and subjecting the roll to radial
vibrations in all directions at an ultrasonic frequency.
9. In the method of roller leveling or straightening a
longitudinally moving elongated metal workpiece by reversely
bending it, the steps comprising directing the workpiece part way
around a hollow roll in engagement therewith throughout an arc of
not more than 90.degree., supporting the roll at points
diametrically opposite the ends of said arc, and subjecting the
roll to radial vibrations in all directions at an ultrasonic
frequency.
10. In the method of roller leveling or straightening a
longitudinally moving elongated metal workpiece by reversely
bending it, the steps comprising directing the workpiece part way
around a hollow roll in engagement therewith through an arc of not
more than 90.degree., and vibrating the roll radially at an
ultrasonic frequency, the roll having a diameter and wall thickness
that provides bell mode resonance when vibrated at said frequency.
Description
The reforming of sheet, strip, or even shapes, which exhibit lack
of flatness or the presence of waves, wrinkles, or bows is
accomplished by a process known as leveling or straightening. In
this process the work is placed under a large tensile or flexural
stressing load of magnitude at or near the yield strength of the
material. The resulting elongation or redistribution of internal
stresses produces a product relatively free of geometrical
irregularities; in other words, it is flat. This working of the
material to straighten it imposes unusually large stresses on the
material and on the machinery performing the leveling process.
It is conventional in leveling processes to feed the metal strip
through a series of deflection rolls while applying a large tensile
stress to it. This flexing of the material alternately applies
tensile and compressive stresses to the strip as it passes through
the series of rolls. It is apparent that the degree of leveling or
flatness obtained for material of a given thickness is sensitive to
roll diameter as well as to tension on the strip. Within a range of
material thicknesses and roll diameters, certain adjustments may be
made between tension and wave depth or flexural stresses to obtain
essentially a flat or leveled workpiece. It becomes progressively
more difficult, however, to process material that is very thin
compared to roll diameter. This is usually attributed to the
inability to apply sufficient flexural stresses to maintain the
plastic state of the material. Decreasing the roll diameter and
increasing the number of rolls to produce sufficient flexural
stresses for leveling very thin strip material increases the
machine design complexity, due to the necessity for maintaining
stiffness in the small diameter work rolls to prevent excessive
flexing or bending between discontinuities of backup rolls. It has
been suggested that the material thickness should be no less than 2
percent of the roll diameter for efficient leveling. This means
that for a material thickness less than 0.010 inches the roll
diameter may become less than 0.500 inches, or even less for
material thinner than 0.010.
To meet the demand for leveling thin strip material without the
need for highly flexible small diameter rolls, a large variety of
roll arrangements of somewhat orthodox design have been developed.
However, the increased complexity of these machines has reduced the
dynamic range of feeds or speeds with which the material may be
processed if efficient leveling is to be preserved.
It is among the objects of this invention to provide for roller
leveling which requires fewer rolls, which is not so dependent upon
the ratio of roll diameter to material thickness as heretofore,
which reduces bearing friction on the rolls, which imposes lower
loads on the leveler, which can operate at higher speeds, which
results in less long-time relaxation in stored material that has
been leveled and which reduces the danger of breakage of strip
material being leveled. Another object is to provide means for
generating in a leveler roll specific modes of high frequency
vibrations that are not readily stalled or rendered static by heavy
loads.
This invention is predicted on the superimposing of two stresses;
i.e., high frequency dynamic stresses on a continuous or static
stress of tension and/or bending. Ultrasonic amplitudes sufficient
to produce a significant strain in the material being leveled are
assisted by the static tension developed between the material
supply and take-up points. Likewise, the tension imposed on the
material is made more effective by the superimposed dynamic
stresses. High intensity ultrasonic energy gives significant
redistribution of residual stresses in the material being leveled
and thereby aids the leveling process.
The invention is illustrated in the accompanying drawings, in
which
FIG. 1 is a longitudinal section through an improved roll in a
roller leveler;
FIGS. 2 and 3 are cross sections taken on the lines II--II and
III--III, respectively, of FIG. 1;
FIG. 4 is a diagram of strip traveling through the roller
leveler;
FIG. 5 is a similar diagram illustrating vibration of the central
roll; and
FIGS. 6, 7 and 8 are diagrams of three different modifications.
Referring to FIGS. 1 to 3 of the drawings, the superstructure or
framework 1 of a roller leveler supports at least three parallel
horizontal rolls. The two outer rolls 2 extend a short distance
down the opposite sides of the intermediate roll 3 and are
adjustable vertically in a well known manner. It is a feature of
this invention that the body of the intermediate roll is a heavy
walled hollow cylinder, the ends of which are sealed. It is made of
low loss metal, such as Inconel or Monel. The sealing preferably is
done by cup-like cases 4 tightly mounted in the ends of the roll
body with their open ends facing outwardly. The roll is supported
in the framework and held against movement sideways by means of
rollers 6 that engage its periphery at its opposite ends. These
rollers are rotatably mounted on studs 7 projecting inwardly from
the framework. Axial movement of the roll is prevented by similar
rollers 8 engaging the end faces of the roll body and rotatably
mounted on studs 9 also supported by the framework.
In accordance with this invention, a series of ferroelectric
transducers 11 is mounted inside the hollow roll body. They are
close to its inner surface, but do not touch it to avoid being
fractured by heavy mechanical loads on the outer surface of the
roll body. These transducers are short hollow cylinders, through
which a support extends. They vibrate radially and are resonant at
or near the point at which roll 3 resonates. The support preferably
is a tube 12 concentric with the roll body, with its ends fitting
in central recesses in the end walls of cases 4. The transducers
can be spaced apart and from the cases by means of O-rings 13 and
14 encircling the tube. The transducers are formed of ferroelectric
ceramic material of the ABO.sub.3 type and have terminals plated on
their opposite sides. They are polarized electrically and the
positive terminals are electrically connected to one another, while
the negative terminals likewise are connected to one another.
In order to energize the transducers, two transformers are used
unless the roll is so short that only one transformer is required.
The terminal wires of the transducers are connected to the inner
ends of metal conductors 15 sealed in glass plugs 16 that are
sealed in holes in the cases. At each end of the roll the outer
ends of these conductors are connected to the terminals of a load
coil 17 or secondary winding in a transformer core section 18 of
moderately high permeability ferrite material held in the case by a
snap ring 19. The outer surfaces of this core section and the
winding or coil are substantially flush with the end surface of the
roll body. Opposing the core section is another core section 21
that is coaxial with it. This core section is rigidly mounted in
the framework and contains a primary winding or drive coil 22
directly opposite the load coil and wound in a manner to match its
impedance. The two core sections are spaced apart by a small air
gap not exceeding 10 mils in width. An air gap of this magnitude is
satisfactory for large magnetic coupling with cores of this type
operating in a frequency range above 20 KHz. The transformers thus
formed furnish electric current from the outside to the
transducers, without mechanical connection, to cause them to
vibrate radially at ultrasonic frequencies while rotating at high
speed. The absence of bonding of the transducers to either support
tube 12 or roll body 3 results in a more efficient and economical
design with less tendency to oscillate in inefficient spurious
modes of vibration.
In order to transmit the vibrations of the transducers efficiently
to the encircling roll body, which is designed to be radially
resonant at the driven frequency, all of the empty space between
the central tube 12 and the inner surface of the roll body is
filled with a suitable low loss oil, such as silicone fluid, that
will not be affected adversely by high frequency vibrations. When
the transformer is energized, the vibrations of the transducers are
transmitted through the oil to cause the roll body to vibrate
radially in all directions. It is necessary that all undissolved
gases be purged from the oil, as gas bubbles would act as acoustic
pressure release bodies due to their expansion and contraction in
the sound field. That would materially reduce the ultrasonic power
delivered to the workpiece.
Since it is necessary that the ultrasonic roll be filled with the
oil and that there be no air pockets, provision is made for thermal
expansion of the oil. This is done by providing an expansion
chamber for the oil. This chamber, or a pair of chambers, are
formed conveniently in the central tube that supports the
transducers. Thus, the tube may be provided with a plurality of
spaced small radial holes 26 that allow oil to enter the tube and
fill the space between a pair of flexible diaphragms 27 spaced a
short distance apart. The diaphragms close the open ends of a pair
of capsules 28 that fit tightly in the tube and face each other.
The capsules contain nothing but air. When the oil in the roll
expands, more of it is forced in between the diaphragms and that
forces them apart and causes them to compress the air in the two
capsules. When the oil cools and contracts, the compressed air in
the capsules expands and holds the diaphragms tightly against the
body of oil between them as oil is forced out of the central tube
to keep the space around it filled. The small size of holes 26
causes them to present a high dynamic impedance to the high
frequency energy generated within the oil, whereby vibrational
energy loss to the pressure release capsules 28 is held to a
minimum.
As shown in FIG. 2, a metal strip 30 drawn through the leveler
under tension from a supply coil is held in engagement with the
vibrating roll 3 by means of idler rolls 2, which are so positioned
that they will direct the strip part way around the roll between
them, but not more than 90.degree.. It will be seen that the strip
is reversely bent or flexed as it leaves one idler roll, passes
across the vibrating ultrasonic roll in engagement therewith and
then under the other idler roll. If, for example, the ultrasonic
roll is approximately three inches in diameter for resonance near
25 KHz, then the strip should extend approximately 21/2 inches
around that roll. Under full power at a moderate figure of merit
for the roll, the peak-to-peak displacement of the vibrating roll
surface may be as high as 400 microinches. The strain produced with
each vibration of that portion of material between the idler rolls
thus exceeds 0.0001 inch per inch. A percentage of the dynamic
strain produced in the material is taken up by the longitudinal
tension maintained in the strip as it travels through the leveler.
One function of idler rolls 2 is the prevention of propagation of
high energy ultrasonics along the strip, which in the case of very
thin and ductile material under high tension could conceivably
produce premature cold working in the material.
With the roll and arrangement of strip just described, all portions
of the roll surface vibrate in phase; that is, they all move in and
out together as indicated by the straight arrows in FIG. 4. This
radial vibration is one of the principal resonant modes of the
hollow roll, but it is subject to deterioration in efficiency by
the loading on the side wall of the roll caused by high tension in
the strip. It can only be efficient when the tension in the strip
is relatively light, such as when thin gauge material is processed.
The radial resonance is determined by the diameter and
circumference of the hollow roll and is independent of wall
thickness so long as the wall is thin compared to the wave length.
Consequently, the fixed resonant parameters of the radial mode
allow little control variation at the power source for
compensation.
In addition to the radial mode, an elliptic or bell mode of
vibration also occurs at the same time as a result of the
unbalanced load on the surface of the roll, due to its contact by
strip material under tension. Thus, vibration of the portion of the
roll in engagement with the strip is restrained, so axes of
symmetry are established for the bell mode, which is characterized
by parallel nodal lines extending lengthwise of the surface of the
roll along the opposite ends of the arcuate surface engaged by the
strip. The nodal lines intersect the upper ends of broken diametric
lines 32 in FIG. 4, while another pair of nodal lines intersect the
lower ends of the broken lines. The bell mode of resonance is a
highly variant mode. For a given diameter or roll, the resonant
frequency depends on wall thickness. As the wall thickness is
increased, the resonant frequency increases.
The instantaneous displacement of the bell mode is seen, greatly
exaggerated, in FIG. 5. That portion of the roll is contact with
the strip at any instant is moving out of phase with the sectors of
the roll at right angles to it. On the other hand, the
diametrically opposite arcuate surface is in phase with the portion
of the roll in contact with the strip. Consequently, as the roll is
squeezed along one diameter it bulges along a diameter at right
angles to the first diameter. The squeezing and bulging then
reverse. The wall thickness at the nodal lines functions as a
compliant spring, whereas the outward or inward moving portions, as
shown by the arrows, function as a distributed mass. The frequency
sensitive features of the bell mode are thus the wall thickness of
the roll, the pressure normal to the wall caused by the tension in
the strip, and the positions of backup rolls when used.
As the load shown in FIG. 5 is increased by increasing tension on
the strip, the resonant frequency of the bell mode is lowered as
though the distributed mass were increased. However, as the idler
rolls 2 are lowered relative to roll 3 to increase the area of the
latter engaged by the strip, the material is brought closer to the
nodal lines, whereby the effective stiffness of the roll in contact
with the strip is increased. The increased stiffness thus tends to
compensate frequency shift due to tension. The superpositioning of
the bell mode vibrations on the fundamental in-phase radial
vibrations makes it extremely difficult to stall the vibrations,
even when the roll is heavily loaded by the workpiece. This is a
great advantage.
Another feature of the idler rolls 2 shown in FIG. 5, is to
maintain a fixed length of strip material between the points of
tangency with the idler rolls, such that this segment of material
is longitudinally resonant at the driving frequency. Most metals
will resonate at approximately 20 KHz if the segment between the
idler rolls is approximately 4 inches in length.
Bell mode vibrations can be enhanced by using a pair of backup
rolls 35 in light contact with the ultrasonic roll, as shown in
FIG. 6. By placing them against the vibrating roll along the lower
nodal lines, they will not interfere with vibrations because there
are none in those locations, which are the neutral points. The
backup rolls also determine the location of nodal lines, and it
becomes apparent that this system made up of roll diameter and wall
thickness, spacing of idler rolls, area of wrap by strip, location
of backup rolls, and the magnitude of tension on the strip, forms a
complete composite oscillator system. In this system, with some
inherent compensation for frequency shift due to variation of one
or more of the parameters mentioned above, a power generator for
the transducers is used which can be tuned in frequency for maximum
efficiency. In addition, the generator may be automatically
controlled in its frequency so that maximum efficiency is always
attained.
A further advantage of the efficiency of the bell mode in
transmitting energy into thin strip material 40 can be realized by
causing the strip to engage the ultrasonic roll 3 at diametrically
opposite sides thereof as illustrated in FIG. 7. With this
arrangement two different lengths of the strip receive energy
simultaneously from a single vibrating roll, and at the same time
the bell mode of vibration is enhanced by the symmetrical loading
of the roll surface. The material should not contact more than a
90.degree. section of the roll surface at any one area of contact,
and the two areas of contact should be diametrically opposite each
other. The loop in the strip that makes this possible may be formed
by a cluster of rolls, such as by a pair of idler rolls 41 mounted
on fixed axes, and a floating roll 42 beneath them. There is
another pair of idler rolls 43 above the vibrating roll to guide
the strip around it. Those sectors of the roll not in contact with
the strip are unrestrained, whereby a preferred bell mode resonance
is obtained in which the desired maximum roll surface displacement
is caused to occur in the centers of the unrestrained areas at top
and bottom of the roll and in the centers of the areas in contact
with the strip at the sides.
The preceding diagrams show the generation, stabilization and
utilization of efficient fundamental mode of resonant vibration.
Higher order bell modes may be generated where it is preferred to
use a larger diameter roll as the ultrasonic roll, but a more
convenient way of attaining higher order bell mode resonances is by
using small backup rolls in specific locations as shown in FIG. 6
or, better yet, as shown in FIG. 8. In the latter diagram four
diametrical nodal areas or a total of eight surface nodes are
indicated. The nodal lines are separated at angles or 45.degree.,
with the bell mode vibration displacement at any instant indicated
by the straight arrows. The strip 50 engages opposite sides of the
ultrasonic roll 3 because it travels around a pair of idler rolls
57 at one side of the vibrating roll. It is held against the latter
by idler rolls 52. It engages only 45.degree. of the roll surface
at each side. The higher order bell mode is generated by
positioning four smaller backup rolls 53 in contact with the
ultrasonic roll. These small rolls are placed between the
strip-engaging areas in positions where their lines of contact with
the ultrasonic roll are intersected by the nodal lines. The small
rolls assure the nodal lines remaining in exactly the desired
positions so that precession will not occur, which would cause beat
notes or rumbles to develop. The centers of the areas of the strip
contacting the ultrasonic roll are located at antinodes of the roll
surface, as is true in every case. High efficiency is due to the
large number of unloaded antinodes. If desired, such as when
leveling heavy gauge material, a large roll 3 may be used that is
not a vibrating roll, and idler rolls 52 may all be ultrasonic
rolls, thereby permitting the utilization of more energy.
In all arrangements utilizing the bell modes, the strip should not
be allowed to span across a nodal line for a given segment of
contact. When greater contact area is required, a plurality of
spaced sectors of contact is used. Each sector should not exceed a
single antinodal portion of the roll. A plurality of idler rolls or
cluster of rolls could be used to bring the strip into contact with
the ultrasonic roll at many different areas of contact. The use of
this feature depends upon material stiffness or thickness
limitations as well as on surface speeds or other processing
requirements. However, better performance and stability of
resonance modes are realized by adhering to diametrical symmetry in
contacting the work surface with either the material being
processed or the higher order idler rolls.
Ultrasonic leveling as described herein has many advantages over
conventional leveling processes. The more important advantages are
summarized as follows:
Lower static tension can be used so that higher speeds are
possible.
Lower static tension causes less strain on the bearings and backup
rolls.
Lower static tension results in less structural failure and less
danger of breaking thin strip material.
Acoustic annealing during leveling yields greater elongation of
strip with lower static tensions.
There is greater diffusion of internal stresses in the work
material.
A controlled work hardened material is produced, due to the cold
working caused by the ultrasonic vibrations.
There is less long-time relaxation in stored material after
ultrasonic leveling because the material has been stress
stabilized.
High frequency stresses are introduced in the presence of static
stresses for the reduction or elimination of polarizing type of
stresses that restrain further plastic deformation of
polycrystalline materials.
The application of ultrasonic vibrations aids considerably in the
relief from residual stresses caused by application of large static
stresses.
According to the provisions of the patent statutes, we have
explained the principle of our invention and have illustrated and
described what we now consider to represent its best embodiment.
However, we desire to have it understood that, within the scope of
the appended claims, the invention may be practiced otherwise than
as specifically illustrated and described.
* * * * *