JPH071045A - Method and device for manufacturing meandering corrugated material - Google Patents

Abstract

PURPOSE:To remarkably improve the structure strength and to attain printing adaptability of a complex corrugated sheet by making the surface flattened and thereby making the corrugated shape of a finally obtd. meandering corrugated sheet uniform. CONSTITUTION:By supplying a width reduced sheet 1 in the process of a roll- forming between a paired rolls 3 for forming so that the width reduction ratio i'k in a plane following progressing corrugated corresponding part 10 is larger than the width reduction ratio i's in a plane preceding progressing corrugated corresponding part 9, the forming work is applied to the meandering corrugated sheet 2. Further, the width drawn-up sheet 1 is preferrably supplied between paired rolls 3 for forming so that the width reduction ratio i'k in the plane following progressing corrugated corresponding part 10 is larger than the width reduction ratio i's in the plane preceding progressing corrugated corresponding part 9 and at the same time, the forming work is applied so that a weight averaged take up ratio jk in the following pressing corrugated corresponding part 10 is larger than that js in the preceding progressing corrugated corresponding part 9.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a serpentine corrugated body having a two-way corrugated corrugated body in which the corrugated body is roll-formed so that the amplitude H of the corrugated corrugated body is substantially uniform. The present invention relates to a method for manufacturing a corrugated corrugated body, and to a manufacturing device for a meandering corrugated body that enables roll forming.

[0002]

2. Description of the Related Art In a conventional roll forming method, a width-adjusting sheet 1 which is a straight corrugated body in the supply direction is previously provided as a uniform width-adjusting ratio in the sheet width direction and is supplied to a forming pair roll to perform a roll forming process. It is best that a certain width-shifting sheet 1'is finally obtained by forming a meandering corrugated body having a two-way corrugation so that a uniform width-shifting rate i can be maintained as much as possible throughout the width direction. To do. A forming roll is a forming roll that adopts a manufacturing method and that has a meandering tooth profile row provided in the axial direction of the roll circumferential surface so that the maximum meshing depth can be made uniform at all parts of the row. It has been adopted.

[0003]

However, roll forming of the tooth profile row provided with a uniform meshing depth in the roll axial direction is performed so that the widthwise moving ratio i which is as uniform as possible in the width direction is maintained. However, in the finally obtained meandering corrugated body, each cross-sectional waveform of the corrugated row is composed of a portion where the waveform amplitude H is large and a portion where the waveform amplitude H is small, and inevitably an uneven waveform shape is generated. It had been.

The cause of such a problem will be described in more detail. A sheet to be processed, which has been width-wise aligned in advance, is supplied to a pair of rolls, and buckling deformation occurs immediately before the forming process is started, so that the sheet is originally uniform in the width direction. Although there is a bias in the width-shifting ratio that should have been blended with, the processed sheet in the roll forming process has a uniform meshing depth at all parts of all the tooth profile rows of the roll. Bending of the sheet near the elastic limit due to molding difficulty is performed at the part where the lateral shift ratio is relatively small, and sheet bending that does not reach the elastic limit due to easy molding is performed at the part where the lateral shift ratio is relatively large. Is done.

As a result, the serpentine corrugated body formed by the tooth profile row having a uniform meshing depth has a uniform corrugated row height, but has a residual stress immediately after it is separated from the paired rolls. Return deformation occurs due to the action, and the return deformation is small at the part that reaches the forming stress close to the elastic limit, while the part that stays at the forming stress far from the elastic limit has the large return deformation, and finally the incomplete shape A meandering corrugated body will be obtained. In each such corrugated row, the difference between the part where the amplitude of the cross-sectional waveform is large and the part where the amplitude is small is remarkable, and when the difference exceeds 5/100 mm, the corrugated body has a two-leaf flat sheet. The reinforced composite corrugated body obtained by pasting the above in a sandwich shape is difficult to be completely integrated, resulting in a significant decrease in various structural strengths, and the composite corrugated body lacking in the flatness of the surface is not properly printed. That problem was pointed out.

In other words, in order to achieve a uniform waveform amplitude at all the row portions in the corrugated row section waveform of the meandering corrugated body to be finally obtained, first, the forming pair should be used. It is essential to make the mesh depth of the tooth profile row of the roll uniform in all tooth profile rows and all row parts. Secondly, the tooth profile row with uniform mesh depth. In order to use the forming rolls, the roll-forming sheet to be roll-formed should be supplied so as to have a uniform width-shifting ratio in the roll width direction, and the uniform width-shifting ratio should be maintained during the roll-forming process. Various trials and errors have been made under the common sense that is essential, but as a result, the above-mentioned fatal technology can not overcome the neck,
A meandering corrugated body and a reinforced composite corrugated body having the expected material strength and printability were not obtained.

The present invention has been made to solve the above-mentioned problems, and the corrugated shape of the meandering corrugated body finally obtained can be made uniform, and as a result, the structural strength is remarkably increased. An object of the present invention is to provide a manufacturing method and a manufacturing apparatus for a meandering corrugated body, which is improved and has a flat surface so that the printability of the composite corrugated body can be improved.

[0008]

In order to achieve the above object, according to the present invention, a width-adjusting sheet which is a straight corrugated body in the supply direction is supplied to a forming pair roll as a uniform width-adjusting ratio in the width direction. In the method of manufacturing a meandering corrugate to be formed, the width-shifting sheet in the roll forming process has a width-shifting rate that is a ratio of a length in a width direction in a flat corrugation and an actual extension developed in the width direction. The characteristic is that the trailing wave is relatively large compared to the preceding wave.

A method of manufacturing a meandering corrugate in which a widthwise aligning sheet, which is a straight corrugated body in the supply direction with a uniform widthwise ratio in the widthwise direction, is supplied to a pair of forming rolls for forming. The width-shifting sheet in the forming process has a width-shifting ratio, which is the ratio of the length in the width direction in the planar corrugation and the actual extension of the widthwise direction, relative to the preceding wave in the trailing wave. In addition, the width-shifting sheet has a length in the width direction in a flat corrugation when the ratio of the cycle in the supply direction in the cross-sectional corrugation to the actual extension developed in the supply direction is taken as the step repetition rate. The weighted average step repetition rate, which is the weighted average of the step repetition rate within the above range, is set to be relatively large as compared with the preceding wave after the trailing wave.

Further, there is provided a meandering corrugate manufacturing apparatus having a pair of forming rolls for forming and processing a widthwise sheet which is a straight corrugated body in the supply direction with a uniform widthwise ratio in the width direction. The paired roll is formed by providing a plurality of meandering tooth profile rows in which the tooth profile for the preceding wave and the tooth profile for the trailing wave are alternately continuous in the axial direction of the roll peripheral surface in the rotation direction of the roll. It is characterized in that the meshing depth weighted average is set relatively large in comparison with the preceding wave tooth profile row by forming the trailing wave tooth profile row.

[0011]

EXAMPLES The present invention was obtained by a completely new idea and thorough demonstration beyond the conventional wisdom, and in each stage from the width-shifting sheet to the final corrugated body in roll forming of the meandering corrugated body. A preferred embodiment in which various problems associated with conventional roll forming can be solved by performing dynamic analysis of shape transition will be described in detail.

FIG. 1 shows a roll-forming process of the meandering corrugated body as a schematic perspective view, in which the width-shifting sheet 1 is supplied to a forming pair roll 3 and molded, and then the meandering corrugated body 2 is formed. Finally obtained,
Although not shown, there is a width-shifting sheet 1'in the roll forming process between the pair of rolls 3.

The width-shifting sheet 1 is a flat corrugated body formed by processing a flat sheet to have a uniform width-shifting ratio in principle, and the pair of rolls 3 is a serpentine tooth-shaped strip in the axial direction of the circumferential surface. The rows are provided in multiple steps in the circumferential direction of the circumferential surface and are installed so as to maintain a predetermined engagement depth, and the meandering corrugated body 2 finally obtained has a two-direction corrugation in the width direction and the supply direction. The meandering corrugated body is provided in multiple stages, the details of which are shown in perspective view in FIG.

FIG. 3 shows a plan view of the meandering corrugated body 2, and if roll forming progresses in the direction of the arrow, the row curved portion preceding in the direction of travel in each corrugated row is defined as the preceding wave 9. The row bending portion that lags in the traveling direction is set as the trailing wave 10, and the center of each bending is set as the leading wave central axis 6,
The center axis of the trailing wave 7 and the boundary between the leading wave 9 and the trailing wave 10 are the neutral axes 8.

Returning to FIG. 1, the width-shifting sheet 1, which is a rectangular corrugated body substantially width-shifted in the width direction, corresponds to the preceding wave central axis 6 and its portion immediately before the start of forming by the pair of rolls 3. Buckling deformation first occurs in the periphery, and the buckling deformation gradually moves toward the portion corresponding to the center axis 7 of the trailing wave with the passage of time, although only momentarily. During the movement of the buckling deformation, the corrugated rows of the width-shifting sheet 1, which are orthogonal corrugated bodies, are drawn from the portion corresponding to the preceding wave 9 to the portion corresponding to the trailing wave 10, and the width-changing rate of the portion corresponding to the preceding wave is increased. Most of them are accumulated in the portion corresponding to the trailing wave, so that the width-shifting ratio is intermittently ubiquitous in the sheet width direction. This phenomenon is suitable for being called "ironing deformation" of the width-shifting sheet 1. Due to the occurrence of the ironing deformation, the width-shifting sheet 1 that should have a uniform width-shifting rate distribution in the width direction is set to have an excessively small width-shifting rate in the preceding wave equivalent portion 6 and in the trailing wave equivalent portion 7. The width-shifting sheet 1'which is supplied to the roll 3 with an excessively large width-shifting ratio and which is deformed from its original shape with the excessively small width-shifting ratio is the meandering that should be finally obtained in the roll forming process. Although the step-up rate required to form the corrugated rows of the corrugated corrugated body 2 is given, the sheet surface is formed in both the roll circumferential direction and the roll width direction with a large sheet deformation stress due to the insufficient width adjustment rate. In the end, a forming trouble such as sheet breakage occurred due to the stretching strain, and the sheet 1 ′ of the trailing wave equivalent portion 7 which was considered to have an excessive lateral shift ratio was subjected to the roll forming process. Regardless of the take-up rate, the width-shifting ratio is so excessive that it is formed as a sheet in which the sheet in-plane relaxation is significant in the roll circumferential direction as well as in the roll circumferential direction, and finally a roll-like excess wrinkle occurs in the roll circumferential direction. However, the subsequent wave sheet formed in a relaxed state under an excessively small forming stress is aimed at suppressing various forming troubles such as returning deformation immediately after the roll is released, and its manufacturing method and its It is a manufacturing device.

The same first wave corresponding biassing sheet 1 in the roll forming process 'is transversely shifting ratio i of the plane trailing wave corresponding portion 10' and the _k in the manufacturing method of the present invention which enables the achievement of the object It is permissible to supply the gap 9 between the forming pair and the roll 3 so as to be larger than the width-shifting ratio i ′ _{s of the} portion 9, and to form into a meandering corrugated body, and more preferably, the width-shifting sheet 1 described above. ′ Is supplied to the forming-to-roll gap 3 at the same time so that the squeezing ratio i ′ _k of the plane trailing wave corresponding part 10 becomes larger than the squeezing ratio i ′ _{s of} the preceding wave corresponding part 9. It is important that the weighted average run rate j _k of the trailing wave equivalent portion 10 is set to be larger than the weighted average run rate j _{s of} the preceding wave equivalent portion 9.

[0017] It should be noted that generally the preceding wave side-to-side rate i _s of,
As shown in FIG. 3, the ratio of the actual extension W of the x-direction sheet (the length in which the bent portion is linearly developed) to the entire area N / 2 of the preceding wave including the central axis of the preceding wave of the planar waveform (W−N / 2) x (2
/ N) × 100 = i _s, and the weighted average stage repeat rate j _{s of} the preceding wave is the actual sheet extension l in the y direction with respect to the period L ₀ of the cross-sectional waveform as shown in FIG. The length (developed in a uniform shape) ratio (l−L ₀ ) × (1 / L ₀ ) × 100 is defined as the step repetition rate, and the weighted average of the step repetition rate in the whole area N / 2 of the preceding wave on the plane waveform.

[Equation 1] Means Figure _{9, j s = (R H} s / L 0) if Shimese the relationship between the preceding wave weighted average amplitude ratio _R H _s / L ₀ of the tooth type ridges in Figure 10 a × beta by reference. _{Let R} H _s be the weighted average of the maximum meshing depths of the roll tooth profile that contributes to forming the deepest amplitude of the cross-sectional waveform of the sheet 1 ′ to be processed, and the cycle of the cross-sectional waveform be L ₀ and the correction coefficient be β.

A feature of the conventional manufacturing method is that in order to manufacture the meandering corrugated body, it is essential that the width-shifting sheet 1'in the roll forming process is uniformly distributed and maintained in the width-wise direction. Based on that premise, we have tried to prevent as much as possible the ironing deformation received by the width-shifting sheet 1 immediately before roll forming, but in the actual production site, the material of the sheet 1 to be processed ,
Roll forming is always accompanied by changes and changes in given conditions such as a given atmosphere and the setting atmosphere of the width-shifting process, running tension of the width-shifting sheet, roll temperature during roll forming, and setting conditions such as the same speed. It is not easy to constantly distribute and maintain a stable width-shifting ratio in the width-shifting sheet 1'after starting. For example, a width-shifting sheet having a tension as close to zero as possible immediately before roll forming has unexpected properties such as its material or humidification amount. Due to the change, the amount of step change fluctuates, and in an extreme case, the tension becomes negative, which causes the width-shifting sheet to remain in the flow direction, and as a result, sometimes the sheet is not locally visible on other general parts. Not able to avoid sudden appearance of trailing waves and preceding waves that are adjacent to the part with the excessive width ratio and the part with the excessive width ratio. Omingu is the meandering corrugated body 2 has been completed, it has been necessary the involvement tear damage advance wave and excessive wrinkles of the trailing wave.

According to the method of the present invention, a predetermined ironing deformation is positively accepted, and a relatively flexible seat buckling that is not easily affected by various changing conditions and changes in setting conditions is promoted. No. 1 is always stable in the y direction and generates regular ironing deformation in the x direction, so that an appropriate width-shifting ratio is properly distributed to appropriate portions of the width-shifting sheet 1'that has entered the roll forming process. ′
Since it is possible to feed the trailing wave at the same time as the leading wave by keeping the predetermined difference width from that of the preceding wave at all times, tearing damage of the leading wave is completed at the completion of forming the final meandering corrugated body. It is possible to effectively prevent the occurrence of excess wrinkles of trailing waves, and more preferably, by the above method, in the width-shifting sheet 1'in the roll forming process, predetermined width-shifting ratios are applied to the trailing wave and the preceding wave. Reliable supply,
While maintaining the difference width of the specified width-shift ratio at all times accurately, the step-up rate required for forming the trailing wave is theoretically larger than that of the preceding wave to the extent of theoretically matching the difference width of the width-shift ratio. At the very least, the meandering corrugated body is formed. As a result, in the corrugated body 2 at the time of final forming, the surplus wrinkles of the traveling wave are let alone to the sheet relaxation, and the tear damage of the preceding wave is to the stretch strain of the sheet. It has become possible to suppress it.

A plurality of manufacturing apparatuses can be considered as specific means for achieving the above method, and a typical one will be exemplified first.

FIG. 6 is a plane waveform of a pair of rolls 3 for forming the meandering corrugated body 2 shown in FIG. 1 in which the tooth profile row group 11 provided on the circumferential surface of the roll is developed and displayed. The solid line waveform is the center line 12 of the top of each tooth profile, and the waveform of the dotted line is the center line 13 of each inter-tooth profile. If the tooth profile row 11 is rotationally moved in the direction of the arrow, in the plane waveform, the part that contributes to the forming process of the preceding wave of the meandering corrugated row 2 is located after the preceding wave tooth pattern 17 and the corrugated row 12. A part of the running wave 10 that contributes to the forming process is a trailing wave tooth profile 18, and the central axes thereof are a leading wave tooth profile center axis 14 and a trailing wave tooth profile center axis 15, respectively. 16

FIGS. 7 and 8 show an axial cross section near the center axis 14 of the leading wave tooth profile and an axial cross section near the center axis 15 of the trailing tooth profile in the state where the pair of rolls 3 mesh with each other. At the center connecting line 19 of the upper and lower rolls, the tooth profile row 11 of the upper roll 3 is deepest meshed with that of the lower roll 3 ', but at that time, the corrugated row cross-sectional waveform amplitude of the meandering corrugated body 2 to be formed is processed. The weighted averages H _s and H _k are substantially determined. That is, the deepest meshing line 20 of the upper roll and the deepest meshing line 2 of the lower roll having the common center of the lower roll 3 '
The shortest distance of 1 is the weighted average of actual meshing depths _R H _s , _R H
Assuming _k , in the manufacturing apparatus of the present invention, the weighted average _R H _k of the actual meshing depths of the trailing wave tooth profile in FIG. 7 is _represented by the weighted average _R H _s of the substantial meshing depths of the preceding wave tooth _profile in FIG. The tooth profile row 11 of the upper and lower rolls 3 and 3'is provided so as to be relatively larger. Specifically, the weighted average _R H _k of the actual meshing depth of the trailing wave tooth profile is set to the preceding wave tooth. As a method of making the die larger than _R H _s , the distance between the top of the trailing wave tooth profile of the lower roll 3 ′ and the center of the lower roll 3 ′, that is, the weighted average of the height of the trailing wave tooth profile
_D R _k is set to be larger than the weighted average _D R _s of the leading wave tooth profile height and the center of the lower roll 3 ′, that is, after the upper roll 3 The distance between the top of the running wave tooth profile and the center of the upper roll 3, that is, the weighted average _U R _k of the heights of the trailing wave profile and the preceding distance between the top of the running tooth profile and the center of the upper roll 3, that is, the leading It is provided to be larger than the weighted average _U R _s of the height of the corrugations, and also the weighted average _D R _{s of the} heights of the trailing corrugations of the lower roll 3 ′ together with the height of the trailing corrugations of the upper roll 3 also it is provided as each size than the weighted average _U R _k of the upper roll trailing wave-toothed height with the weighted average _U R _s of the preceding wave-toothed height of the lower roll 3 'and the weighted average _U R _k of the Both are effective for the present invention.

In the future, the weighted averages H _s and H _k of the corrugated row cross-sectional waveform amplitudes will be respectively set to the same cross-sectional amplitudes H _s and H _k, and the weighted averages _R H _s and _R H _k of the substantial mesh depth will be respectively calculated. The engagement depths _R H _s and _R H _k are abbreviated.

Immediately before roll forming, the width-shifting sheet 1 is allowed to undergo a slightly loose ironing deformation that does not require strict adjustment and control of conditions such as setting atmosphere and running tension according to the sheet material. Then, the roll forming is started, and the width-aligning sheet 1'which has undergone a predetermined ironing deformation in the forming process is formed as a leading wave because a stable and reliable distribution of the width-alignment ratio is performed in both x and y directions. In the width-shifting sheet 1'to be formed, the width-shifting ratio has a small predetermined value, and in the width-shifting sheet 1'to be formed as a trailing wave, the width-shifting ratio has a large predetermined value. Always controlled. The leading wave equivalent portion sheet 1'having a small width-shifting ratio is formed so that the forming stress does not become excessively large due to the leading wave tooth mold 17 provided with a relatively shallow meshing _R H _s. The trailing wave equivalent portion sheet 1'having a large lateral shift ratio has a relatively deep meshing _R H _k . The trailing wave tooth mold 18 provided so that the forming stress is not excessively small. It is formed into a width-shifting sheet 1'close to the meandering corrugated body 2 of the final shape.

[0025] As a result, it is appreciated that the maximum cross-sectional amplitude of the preceding wave corresponding portion of the centering seat 1 'during roll forming complete with _O H _s is meshing depth _R of the preceding wave-toothed 17
Since the H _s, and the maximum cross-sectional amplitude _O H _k of the trailing wave corresponding section is formed by respective most approximate to the meshing depth _R H _k of the trailing wave-toothed 18, the preceding wave corresponding portion maximum section amplitude _O H _s is set to be relatively smaller than the trailing wave same amplitude _O H _k , but immediately after that, the meandering corrugated body 2 released from the external forming force is not rarely accompanied by a shape change, and especially For semi-elastic plastic materials such as, for example, and plastics that have the same degree of anti-plasticity and anti-elasticity as paper, the residual stress immediately after molding and the return deformation due to it cannot be ignored, so design it in advance. Preformed tooth profile 17
The sheet 1'of the preceding wave corresponding portion formed by the shallow meshing _R H _s of the tooth is so close to the elastic limit that the return deformation after leaving the roll is slight. The sheet 1'corresponding to the trailing wave formed by the depth _R H _k is kept slightly in front of the elastic limit so that the return deformation after the roll is released appropriately occurs in each tooth profile of the leading wave and the trailing wave. The difference between the meshing depths of the rows is properly determined. As a result, the meandering corrugated body 2 whose shape is stable at the stage where the return deformation is stopped after the completion of the roll forming is eliminated and the return wave section amplitude H _s and the trailing wave section amplitude H _k are as large as possible. It was obtained as close to that value.

Further, the main steps of roll forming by the manufacturing method and the manufacturing apparatus of the present invention at the time of roll forming will be described with reference to specific cross-sectional waveform diagrams. Corrugated rows from the completion of roll forming to the stabilization of its shape. 4 and 5 show the variation of the sectional waveform, and in FIG. 4 showing the trailing wave sectional waveform and FIG. 5 showing the preceding wave sectional waveform, the dotted waveform shows the corrugated body 1'when the roll forming is completed. The waveform of the solid line is that of the corrugated body 2 which is substantially separated from the roll tooth mold after the completion of roll forming.

[0027] Row wave 10 after the corrugated ridges at roll forming is completed, the maximum amplitude _O H of the sectional waveform
maximum amplitude of the _k (which approximates the tooth die meshing maximum depth _R H _k of the trailing wave 18) to the preceding wave sectional waveform _O H _s (prior-toothed meshing maximum depth of wave 17 _R H _s Since each of them is formed and processed by a predetermined design width to be larger than that of the trailing wave, the trimming rate and run rate required by the trailing wave are larger than the trimming rate and run rate required by the trailing wave. Is set to a predetermined value. On the other hand, the trailing wave of the corrugated row is supplied at a step rate equivalent to that of the trailing wave, but the tailing rate of the trailing wave supplied by ironing deformation is significantly larger than that of the preceding wave. To be big. From the above, the degree of return deformation due to residual stress after roll separation is significantly different between the trailing wave and the preceding wave, and the supply of both the shift ratio and the carry rate is below the demand, that is, a tight supply-demand relationship. In the corrugated row preceding wave, the cross-sectional amplitude _{O of the} corrugated row preceding wave is reduced with the amount of return deformation being small.
It is changed from H _s to H _s, the supply of both the shift ratio and the carry rate exceeds the demand, that is, the corrugated row trailing wave in the loose supply-demand relationship makes the return deformation amount large, It is caused to vary its cross-sectional amplitude _O H _k -H _k. By adjusting the variation range _O H _s -H _s prior wave amplitude and variable width _O H _k -H _k of the trailing wave amplitude, i.e. dunk rate both with the lateral move ratio in the preceding wave 9 and trailing wave 10 In the meandering corrugated body 2 which is finally obtained by optimizing the respective supply and demand, the cross-sectional waveform amplitude H _k of the following wave 10 and the cross-sectional waveform amplitude H _s of the preceding wave 9 both approach each other infinitely. It can be done.

Furthermore, one basic step will be given to systematically explain all the basic principles of the roll forming method according to the present invention and the main functions of the roll forming apparatus.

In the first place, the meandering corrugated body having a two-way waveform has an amplitude ratio H / L of a cross-sectional waveform and a meandering ratio D / of a plane waveform.
It is a pure mathematical structure that is formulated as a function relation of H / L = fi (D / N) where the width-shifting ratio i is a parameter constant as two parameters having N, and its respective forms,
It also corresponds to the unique shape curve that determines the shape. It exists only when the two-way corrugated corrugated body is obtained as a flat sheet and is bent and deformed substantially without in-plane stretching strain, and the corrugated body is bent. This means that the structure is a very difficult and definite structure that can be completely restored to the original flat sheet by releasing the deformation.

The shape curves are shown in FIG. 9 and FIG. 10, which are a group of hyperbolas distributed in parallel with the vertical and horizontal coordinate axes as asymptote. Each parallel hyperbola is specified by the i value of the parameter constant, and The H / L value and the same D / N value are each given a unique eigenvalue. In other words, when the parameter D / N value is fixed, the unique parameter H / The L value is determined. In other words, if the width-shifting ratio is given with the meandering ratio being constant, there is only one width-shifting ratio that satisfies the width-shifting ratio.

Each shape of the width-shifting sheet 1 and the meandering corrugated body 2 after completion of roll forming in each process of roll forming using the above-mentioned shape curve group, and associated parameter H / L value, D / N. In order to clarify the change transition of the value and the constant i value, the shape change of the corrugated body by the conventional roll forming method and the forming roll apparatus is shown in FIG. 9, and FIG. 10 is the same as the roll forming method of the present invention. The shape change of the corrugated body by the device is shown.

A plurality of shape curves shown on the coordinates common to both figures indicate the corrugated bodies 1'and 2 at the respective stages of roll forming during the forming process, the completion of the forming process, and the stabilization of the same form and the roll tooth profile row. It corresponds to the wave shape and the trailing wave shape.

Not only the corrugated body 1'in the roll forming process but also the corrugated body 1 which is released from the external forming force after the roll forming and is basically attracted to and maintained by the roll tooth mold is restrained from being deformed in its planar waveform. Therefore, the meandering rate is constant as D _O / N _O × α through the three stages of roll forming.

Accordingly, the respective shapes of the preceding wave and the following wave of the corrugated body 1'2 at each stage of roll forming are on the intersection of the six shape curves and the vertical axis D / N = D _O / N _O × α. , And the shape of the preceding wave is the intersection A, C,
The same E is given, and the trailing wave shapes are given as intersections B, D, and F.

More specifically, the intersection points A and B are the possible leading and trailing wave shapes of the supplied corrugated body 1'in the course of forming, which are biased by the ironing deformation. , C are the leading wave shapes of the corrugated body 1 ′ at the time of completion of forming and the trailing wave shapes of the corrugated body 1 ′ at the time of completion of forming, where the leading edge waves are approximately the maximum meshing depth. It is shown as a tooth shape and a trailing wave tooth shape, and the respective leading and trailing wave shapes of the corrugated body 2 where the intersection points E and F are substantially released from the residual stress released from the external forming force are shown. Has been done.

When the parameter H / L is the substantial amplitude ratio of the corrugated strip cross-sectional waveform, (H _O / L _O ) ×
β is its individual value, where H _O / L _O is the apparent amplitude ratio, H _O is the fluctuation value of the cross-sectional waveform amplitude, L _O is the fixed value of the cross-sectional waveform period, and β is the top and bottom shapes of the cross-sectional waveform. It is a correction coefficient. _{Incidentally, H 's, R H s} , H s is a preceding wave each amplitude weighted _{average, H' k, R H k} , H k is the weighted average trailing waves each amplitude. If the parameter D / N is the substantial meandering rate of the corrugated row plane waveform, (D _O / N _O ) × α is its individual value, and if D _O / N _O is the apparent meandering rate, D _O is the plane. A fixed value of the waveform amplitude, N _O is a fixed value of the planar waveform period, and α is a correction coefficient determined by the top and bottom curved shapes of the planar waveform.

Next, the roll forming process by the conventional manufacturing method and apparatus will be described in detail with reference to the shape curve of FIG.

Coordinate points E and F on the graph respectively show the preceding wave shape and the following wave shape of the final deformed corrugated row after the completion of molding, and the points E and F are significantly separated. The shift is the interval (H _s / L _O ) × β− (H
_k / L _O ) × β = (H _s −H _k ) × β / L _O
This means that the cross-sectional amplitude Hs of the preceding wave must be larger than the cross-sectional amplitude Hk of the trailing wave. This preceding wave ridges of the centering rate during roll forming the output gap i _'s - C point defined by _R i _s and A point interval _{(R
H s / L O) × β-} (H 's / L O) × β = (R H s -
H ′ _s ) × β / L _O, that is, the tooth profile row actually provided from the preceding wave cross-section amplitude H ′ _{s of} the fictitious corrugated row that theoretically corresponds to the width-shifting ratio i ′ _s given as being smaller than the ironing deformation Since the preceding wave cross-section amplitude _R H _{s of} is too large, the supplied sheet is formed into a predetermined shape while the sheet quantity is significantly short of the sheet demanded in both the x and y directions. Leading wave corrugated row 3
Is beyond the elastic limit of the sheet, and plastic deformation due to stretching strain immediately before tearing is caused, so that the return deformation after substantially leaving the roll remains fine, and as a result, it is closer to the point C of the preceding wave shape of the tooth profile row. The preceding wave final shape E point of the corrugated row is shifted to the position. In addition, the width shift ratio gap i ′ _k − _R i during roll forming of the trailing ripples
distance point B and point D determined by _{k (R H k / L O} ) × β-
(H ' _k / L _O ) × β = ( _R H _k −H ′ _k ) × β / L _O
That is, the row wave sectional amplitude after-toothed ridges than _k 'line wave sectional amplitude H after imaginary corrugated ridges commensurate theoretically to _k' excessive and is biassing index i given by the squeezing deformation _R
By making _Hk extremely small, a trailing wave corrugate in which the supplied sheet is formed into a predetermined shape with the amount of the sheet excessively exceeded that of the sheet demanded in both the x and y directions. Since the row is in a relaxed state that does not reach the elastic limit of the sheet, the return deformation cannot be ignored after the roll is substantially separated, and as a result, it is far below the point C of the trailing wave shape of the tooth profile row. The final point F of the corrugated row trailing wave was forced to shift.

In order to eliminate such an undesired situation, that is, as a means for reducing the distance between the shape E point and the shape F point and bringing them closer, the shape A point and the shape B point are changed. It was to reduce the difference as much as possible by setting the feed misalignment ratios of the preceding wave equivalent part and the trailing wave equivalent part of the width-shifting sheet 1'by ironing so that they can be arranged closely in advance. For details, the amplitude of the preceding wave in the tooth row is _R H _s
When the conventional forming roll is characterized in that the amplitude of the trailing wave _R H _k is set to the same value without any difference, the width-adjusting sheet 1 ′ in the roll forming process is used.
Then, the width difference ratio i ′ _{s of the} preceding wave equivalent portion and the width difference ratio i ′ _k of the trailing wave equivalent portion has a difference width i ′ _s ≦ i ′ _k <
It is necessary to supply 1.1 i ′ _s so that the corrugated body has a stretching strain of the preceding wave in its final shape as long as the x and y distributions of the width-shifting ratio as the difference width are always maintained. Without the relaxation of the trailing wave,
Further, the difference between the preceding wave cross-section amplitude H _s and the following wave cross-section amplitude H _k was constantly suppressed to 0.05 mm or less for molding. However, the difference width of the supply deviation ratio between the preceding wave and the following wave is i ′.
The _s ≦ i _'k <1.1i' squeezing deformation inhibiting for maintaining _s, as before roll forming as described above, in, many appropriate given conditions in each process after, thereby always satisfy the specified condition Is essential, it means that extremely extreme adjustments and controls are required at the production site, and due to the difficulty of always satisfying these conditions, sudden large-scale local ironing deformation often occurs. Therefore, the shape A point and the shape B point are extremely separated from each other, and further, the final separation between the shape E point and the shape F point is seldom increased. Was not. In other words, the effort to minimize the difference in the width-shifting ratio has contributed to the problem during roll forming of the corrugated body.

Next, the roll forming process by the manufacturing method and the manufacturing apparatus of the present invention will be described in detail with reference to the graph of FIG. 10. The coordinates E and F on the graph are the preceding wave shapes of the corrugated body 2 at the final stage. And the trailing wave shape are shown respectively, and it is characteristic that both points shift to the close position. It means that the interval (H _s −H _k ) × β / L _o between both E and F points, that is, the preceding wave section amplitude H _s can take a value that is remarkably approximate to the following wave section amplitude H _k . .

[0041] It preceding wave ridges of roll forming during the centering rate output gap i _'s - _R i interval shape point C and the point A defined by _{s (R H s -H' s} ) × β / L O Therefore, that is, that is, the cross-sectional amplitude H ′ _s of the fictitious corrugated row that theoretically corresponds to the width-shifting ratio i ′ _s, which is given as a little undersize by the ironing deformation, is actually provided. Since the _R H _s is relatively large, the demand amount is greater than the sheet supply amount, and the preceding wave corrugated row formed by the forming process is tightly plastically processed beyond the elastic limit of the sheet. Therefore, the return deformation after the roll is substantially left is minute, and as a result, the final corrugated row preceding wave shape E point is shifted to the vicinity of the tooth profile row preceding wave shape C point. Kataya biassing rate demand gap i during roll forming in the corrugated ridges trailing wave _'k - _R i interval shape point B and the point D defined by _{k (R H k -H' k} ) × β / L O From that,
Depth had row wave meshing after tooth type ridges against _k 'amplitude H of the row wave sectional waveform after theoretically commensurate with imaginary corrugated ridges on _k' i.e. ironing biassing ratio i provided as excessive by deformation by provided so as that not to become too small is _R H _k, corrugated ridges trailing wave is allowed molding is slightly Shitamawaru supply and demand the supply amount of the sheet the sheet elastic limit The return deformation after the roll is released is not so large because it is placed relatively close to the corrugated row and the final shape F of the trailing wave of the corrugated row is the point D of the trailing wave of the tooth row. Can be shifted to a position near the point C of the preceding wave shape of the lower tooth row.

Therefore, the condition for achieving such an effect is that the difference _R H _{k −R} H _s between the preceding wave meshing depth and the trailing wave meshing depth of the tooth profile row is caused by the ironing deformation. It is to be provided so as to correspond to the difference i ′ _k −i ′ _s between the trailing wave supply width deviation ratio and the preceding wave supply width deviation ratio in the gathering sheet 1 ′, but it is preferable that it be provided in the actual production plant. When using various pulp sheets such as corrugated cardboard and plastics having the same degree of anti-plasticity and anti-elasticity as paper as the sheet 1 to be processed, the difference in mesh depth between the preceding wave and the following wave of the tooth form row _R H _k - is to provide a tooth form ridges of _R H _s was in advance wave intermeshing depth _R H _s 15% 1.2% paired in the manner allowed to roll 3.

As described above, the meshing depth difference _R between the tooth profile rows
By providing H _{k −R} H _s between the leading wave and the trailing wave, the leading wave shape A point and the trailing wave are initially present regardless of the uneven distribution of the feeding width-shifting ratio of the width-shifting sheet 1 ′. The distance between the preceding wave shape E point and the following wave shape F point of the corrugated row 2 is decreased while the distance between the shape B points is increased, so that mutual proximity shift is finally realized. In other words, the preceding wave and the trailing wave of the final corrugated body 2 can be formed without a great effort to bring the leading wave shape A point and the trailing wave shape B point of the width-shifting sheet 1'in advance. Cross-section amplitude difference H _k −
It was possible to easily keep H _s within 0.05 mm, which brought out extremely useful results as follows. Since it is not necessary to use the nerve for the close shift of the points A and B, the atmosphere for the sheets 1 and 1'to be processed, which is indispensable in the conventional manufacturing method and apparatus, and the ultimate adjustment and control of the running tension can be performed. While being released, the local tear damage and excess wrinkle troubles that accompany roll forming of the meandering corrugated body 2 are completely suppressed despite the variation in the material itself of the sheets 1, 1'to be processed. As a result, stable product production has become possible.

Therefore, in the manufacturing method and manufacturing apparatus of the present invention, the forming and processing conditions, which were conventionally desired, are discarded and a new realistic condition is adopted by a drastic change in the idea. acceptable actively ironing deformation occurs just before, the centering seat 1 '1.2i the x direction ubiquitous distribution of the biassing rate' _s ≦ i _'k ≦ on the roll forming process associated therewith
The range is set to 5.0i ' _s, and more specifically, it is predicted from the material characteristics of the sheet 1 to be processed to be roll-formed, the x-direction initially given, and the ratio of width-shifting and the setting atmosphere. Taking into account the amount of squeeze deformation, the eigenvalue of the more strict difference width of the supply width deviation ratio between the preceding wave and the trailing wave was estimated, and then based on the estimated difference width of the supply width deviation ratio. The desired tooth profile by carefully considering the processing speed during roll forming, the same heating temperature level, the flatness of the corrugated row and the shape of the corrugated section that should be finally expected, as well as the design differences in the section amplitude, High & Low, etc. Difference width of meshing depth is 15.0
_{% ≧ (R H k - R} H s) × 100 / R H s ≧ 1.2 intermeshing depth% and the preceding wave roll-toothed ridges from the scope and the following wave _R H _{s, R} H _k It is preferable that the eigenvalue of is finally selected and determined.

Since the meshing depths _R H _s and _R H _k are weighted average values of the meshing depths of the preceding wave and the trailing wave of each tooth profile row, it can be seen that There are multiple ways of distributing the meshing depths at the parts. Specifically, as shown in FIGS. 7 and 8, the distances _U R, _D R from the center of the lower roll to the top of the tooth profile row are shown. (Hereinafter, referred to as tooth profile height R) is to be changed at each part on the row top center line 12, but first, from the leading wave central axis 14 to the neutral axis 16 toward the trailing wave central axis 15. It is effective to simply and continuously increase the tooth profile height from the leading wave to the trailing wave as a rate of change proportional to the tangent inclination angle θ of the top line 12 of each tooth profile row. It is effective to increase to a predetermined width in the x direction near the center axis 14 of the preceding wave and the center of the trailing wave. 15 Tooth heights R are not changed at a predetermined width in the x direction, and both flat portions are provided, and a predetermined drop is provided on both tooth heights R, and both flat portions are made smooth by the inclined portion. It is also effective to provide a tooth profile so as to be connected, and there are many other measures, and the selection is made in consideration of the material characteristics of the sheet to be processed, the setting conditions during roll forming, and the like.

There are many effective measures other than the above embodiment, and as shown in FIGS. 7 and 8, the maximum contact width between the tooth profile row 11 and the sheet 1'to be processed during roll forming (however, the tooth profile will be described later). It is also possible to increase the tooth profile height from the preceding wave tooth profile 17 toward the trailing wave tooth profile 18 in the same tooth profile row so as to make the above-mentioned tooth profile height 17 higher. Is effective for the present invention as well as a measure for smoothly increasing the size of the trailing wave tooth profile 18, and it is naturally effective for the present invention to use both measures together. In the row plane waveform, the weighted average value θ _k of the tangent line inclination angle θ of the trailing wave tooth profile 18 is calculated from the weighted average value θ _s of the tangent line inclination angle θ of each portion in the x direction on the top center line 12 of the preceding wave tooth profile 17. It is also effective for the present invention to further increase the scent, and the scent of leading wave and trailing wave is also preferable. The weighted average R _s and the R _k at the same time the tooth die height be provided a difference in the tangential tilt and angle theta _s and the theta _k
The anti-roll 3 having a difference in the above is also effective for the roll forming method and apparatus of the present invention.

In the pair of rolls 3 of the present invention, the weighted average R _s of the tooth profile heights and R _k should be different from each other when the two rolls are the targets, and the remaining one roll is R. _In some cases, _s and R _k may be equal to each other, and both are effective, but in particular, a glue roll and a heat press roll for bonding the meandering corrugated body 2 after roll forming and the flat plate liner are substantially used. to tooth type ridges on one side of the forming roll having no operative contact provided the difference in R _s and R _k are the provided the difference in R _s and R _k are the one left side roll with ditto work What is characterized by not having such an advantage is that both the peripheral surfaces of the glue roll and the press roll can be made flat in the axial direction.

Although various concrete measures relating to the present invention have been illustrated above, it goes without saying that any appropriate combination thereof is effective.

[0049]

With the manufacturing method and the manufacturing apparatus of the present invention, it is possible for an expert to precisely and sustain the variation of various conditions such as the material of the sheets 1, 1'to be processed, the given or set atmosphere, the product manufacturing speed and the like. The meandering corrugated body 2, which is the final product, can be mass-produced without requiring mechanical adjustment control. Further, in the meandering corrugated body 2 which is the final product, the maximum difference H _k −H _s between the preceding wave section amplitude H _s and the following wave section amplitude H _k of the corrugated row is kept within 5/100 mm,
While stabilizing, it is possible to constantly suppress the stretching strain of the sheet, which tends to occur in the corrugation row preceding wave, and the sheet relaxation and excess wrinkle, which tend to cause tear damage in the corrugating row trailing wave. In addition, the dimensional accuracy in all parts of the corrugated row was greatly improved, and substantially uniform and high structural strength could be achieved. as a result,
The meandering corrugated body obtained by improving the productivity dramatically due to the high yield and high-speed molding process is integrated with the single-liner meandering corrugated one-sided composite and bi-leaf liner As a meandering corrugated double-sided composite, the secondary commercialization was attempted.Both of the composites maintained the flatness of the liner surface and promised high in-plane compressive strength and high out-of-plane bending strength. It goes without saying that excellent printability of the liner surface was obtained.

[Brief description of drawings]

FIG. 1 is a perspective view schematically showing a roll forming process of a meandering corrugated body having a two-way waveform.

FIG. 2 is a perspective sectional view of the meandering corrugated body.

FIG. 3 is a plan view of the meandering corrugated body.

FIG. 4 is an S _k -S _k cross-sectional view of a meandering corrugated body, S _s
It is a -S _s cross section.

5 is a meandering corrugated body S _k -S _k similar to FIG.
Sectional view, a S _s -S _s cross section.

FIG. 6 is a developed plan view of a tooth profile row on the peripheral surface of the forming roll.

7 tooth type ridges of _R H _s - _R H _s cross section, _R H _k -
Is _R H _k sectional view.

[8] of similar-toothed ridges and FIG 7 _R H _s - _R H _s cross section, _R H _k - is _R H _k sectional view.

FIG. 9 is a transition diagram of a corrugated body shape during a conventional roll forming process based on a shape curve of a two-way meandering corrugated body.

FIG. 10 is a transition diagram of the corrugated body shape during the roll forming process of the present invention based on the shape curve.

[Explanation of symbols]

1 width-shifting sheet (processed sheet immediately before processing) 1'processed sheet in the process of processing 2 meandering corrugated body with two-way corrugation 3, 3'forming vs roll 4 corrugated row top center line 5 corrugated row bottom center Line 6 Corrugated row leading wave center axis 7 Corrugated row trailing wave central axis 8 Corrugated row neutral axis 9 Corrugated row leading wave 10 Corrugated row trailing wave 11 Serpentine tooth form row 12 Tooth top center line 13 Center line of bottom of tooth profile 14 Center axis of tooth profile of trailing wave 15 Central axis of tooth profile of trailing tooth 16 Neutral shaft of tooth profile 17 Leading tooth profile row of 18 tooth trailing profile of tooth profile 19 Roll center connecting line 20 Upper roll the deepest meshing line 21 lower roll deepest meshing line N _O corrugated body plan waveform period D _O corrugated member apparent plane wave amplitude L _O corrugated member apparent cross-sectional waveform period H _s final corrugated member Column preceding wave sectional apparent weighted average H _k final apparent ridges trailing wave section of the corrugated bodies weighted average x-direction corrugated ridges axis direction amplitude, Same as left width direction y-direction corrugated ridges axis direction orthogonal amplitude Same as left flow direction,
Roll Forming direction _O H _k forming roll process corrugated strip weighted average _O H _s forming roll process corrugated strip weighted average _R H _k rolled-toothed ridges trailing the preceding wave sectional maximum amplitude of the column line wave sectional maximum amplitude after the column the weighted average of the wave intermeshing depth _R H _s tangential gradient of the roll-toothed ridges preceding wave meshing depth of the weighted average theta _s first wave-toothed center line of the tangential gradient theta _k trailing wave-toothed center line _U R _s Upper roll tooth profile Weighted average of leading wave height _U R _k Upper roll tooth profile Trailing wave Weighted average of row height _D R _s Lower roll tooth leading wave height _D R _k Lower roll tooth trailing wave height W W tooth top width (maximum contact width between the sheet and the tooth) i _s , i _k , i ′ _s , i ′ _k , _R i _s , _R i _k Alignment ratio H / L of the final corrugated body substantially meandering ratio H _s / L _O of the real amplitude ratio D / N final corrugated _{body, H k / L O, H} 's / L O, H' k /
L _O , _R H _s / L _O , _R H _s / L _O Apparent amplitude ratio of final corrugated body D _O / N Apparent meandering ratio α, β Correction coefficient

Claims (3)

[Claims] 1. A method for producing a meandering corrugate, which comprises forming a width-wise corrugated sheet as a straight corrugated body having a uniform width-wise corrugating rate in a width direction into a pair of forming rolls and forming the corrugated corrugated sheet. The width-shifting sheet in the forming process has a width-shifting ratio, which is the ratio of the length in the width direction in the planar corrugation and the actual extension of the widthwise direction, relative to the preceding wave in the trailing wave. A method for manufacturing a meandering corrugated body, which is characterized in that 2. A method for producing a meandering corrugate, which comprises feeding a width-adjusting sheet, which is a straight corrugated body in the supply direction, as a uniform width-shifting ratio in the width direction, to a pair of forming rolls to perform a forming process. The width-shifting sheet in the forming process has a width-shifting ratio, which is the ratio of the length in the width direction in the planar corrugation and the actual extension of the widthwise direction, relative to the preceding wave in the trailing wave. In addition, the width-shifting sheet has a length in the width direction in a flat corrugation when a ratio of a cycle in the supply direction in a cross-sectional corrugation and an actual extension developed in the supply direction is set as a step repetition rate. Of the meandering corrugated body characterized in that the weighted average stepping rate, which is the weighted average of the stepping rate within the height, is set to be relatively large as compared with the preceding wave. Production method. 3. A meandering corrugate manufacturing apparatus having a pair of forming rolls for forming and processing a width-adjusting sheet which is a straight corrugated body in the supply direction with a uniform width-shifting ratio in the width direction. The paired roll has a plurality of meandering tooth profile rows in which the tooth profile for the preceding wave and the tooth profile for the trailing wave are alternately continuous in the axial direction of the roll peripheral surface in the rotation direction of the roll,
The mean depth of meshing of the tooth profile row is set to be relatively large as compared with the preceding wave tooth profile row by using the trailing wave tooth profile row. Manufacturing equipment.