A sheet of cold rolled material having on both of its surfaces rows of projections and rows of depressions, the projections on one surface corresponding with the depressions on the other surface, the relative positions of the projections and depressions being such that lines drawn on a surface of th
A sheet of cold rolled material having on both of its surfaces rows of projections and rows of depressions, the projections on one surface corresponding with the depressions on the other surface, the relative positions of the projections and depressions being such that lines drawn on a surface of the sheet between adjacent rows of projections are non-rectilinear, the sheet having a base gauge G, wherein each projection has a substantially continuous region of peak plastic strain at, toward or about its apex and/or is thinned by no more than 25% of its base gauge G. Methods of forming the sheet material and tools for forming the sheet material are disclosed.
대표청구항▼
1. A tool (20) for cold rolling sheet material having a base gauge G, the tool being cylindrical and having an axial dimension extending along an axis of rotation and a circumferential surface having a circumferential dimension extending orthogonally to the axial dimension, the tool having rows (R12
1. A tool (20) for cold rolling sheet material having a base gauge G, the tool being cylindrical and having an axial dimension extending along an axis of rotation and a circumferential surface having a circumferential dimension extending orthogonally to the axial dimension, the tool having rows (R12, R13) of teeth (30, 130, 230, 330, 430, 630) extending from the circumferential surface, each tooth having a rounded sheet engaging surface, each tooth (30, 130, 230, 330, 430, 630) having: a first radius r1 extending along a first direction;a second radius r2 extending along the axial dimension;a third radius r3 extending in a third direction orthogonal to said first direction, said first and third directions extending between said axial and circumferential directions, said third radius r3 being equal to a radius of curvature R at and adjacent the peak (11, 31a, 41a, 61a) of each tooth, and the pitch between adjacent teeth in a row being at least 3R, said radius of curvature R providing a balance between maximizing work hardening and minimizing sheet material thinning; anda fourth radius r4 extending along the circumferential dimension and wherein at least one of the four radii r1 to r4 is different from the others. 2. A tool according to claim 1, wherein the second radius r2 is the same or less as the first radius r1. 3. A tool according to claim 1, wherein teeth are arranged in helical rows. 4. A tool according to claim 1, wherein each tooth has a substantially square base, in plan. 5. A tool according to claim 1, wherein each tooth is a four lobed base, in plan. 6. A tool according to claim 1, wherein the tool is for cold forming sheet material having a base gauge G of 2 mm or greater, each tooth having a rounded sheet engaging surface with a radius of curvature greater than or equal to 2 mm and a pitch P of less than 26 mm. 7. A tool as claimed in claim 6, wherein the pitch P is less than 15.6 mm. 8. A tool as claimed in claim 1, wherein the tool comprises a cylindrical roll rotatable about an axis. 9. An apparatus comprising first and second tools for cold rolling sheet material having a base gauge G, each of the first and second tools being cylindrical and having an axial dimension extending along an axis of rotation and a circumferential surface having a circumferential dimension extending orthogonally to the axial dimension, each tool having rows (R12, R13) of teeth (30, 130, 230, 330, 430, 630) extending from the circumferential surface, each tooth having a rounded sheet engaging surface, each tooth (30, 130, 230, 330, 430, 630) having: a first radius r1 extending along a first direction;a second radius r2 extending along the axial dimension;a third radius r3 extending in a third direction orthogonal to said first direction, said first and third directions extending between said axial and circumferential directions, said third radius r3 being equal to a radius of curvature R at and adjacent the peak (11, 31a, 41a, 61a) of each tooth, and the pitch between adjacent teeth in a row being at least 3R, said radius of curvature R providing a balance between maximizing work hardening and minimizing sheet material thinning;a fourth radius r4 extending along the circumferential dimension and wherein at least one of the four radii r1 to r4 is different from the others; andthe rotational axis of the first tool being parallel to the rotational axis of the second tool, the geometry and position of the teeth and the spacing of the tools being such that the teeth on the first tool extend, in use, into gaps between the teeth on the second tool with a minimum clearance between the opposing teeth which is at least equal to the base gauge G of the material to be passed through the apparatus. 10. A sheet steel cold forming tool for cold forming sheet steel material having a base gauge G of 2 mm or greater, the tool comprising: a cylindrical shape and having a rotational axis; andan array of teeth on its outer surface arranged in rows and columns, each tooth having a rounded spheroidal or hemispherical sheet engaging surface free of sharp corners with a radius of curvature greater than or equal to 2 mm and a pitch P between 2.5 and 13 times said base gauge G, the radius of curvature extending in a direction between the rotational axis and a direction orthogonal thereto and wherein said radius of curvature provides a balance between maximizing work hardening and minimizing sheet material thinning for cold forming sheet steel material. 11. A sheet steel cold forming tool for cold forming sheet steel material, the tool comprising: a cylindrical shape and having a rotational axis; andan array of teeth arranged in rows and columns on its outer surface, wherein each tooth has a rounded sheet engaging surface with a first radius of curvature extending in a direction between the rotational axis and a direction orthogonal thereto, a second radius of curvature extending in the direction of the rotational axis and a third radius of curvature extending in a direction orthogonal to the first direction, wherein the first, second and third radii of curvature are equal, the pitch between adjacent teeth in a row being between 3.0 and 3.9 times the first radius of curvature for cold forming sheet steel material. 12. A sheet steel cold forming apparatus comprising a pair of tools for cold rolling sheet steel material having a base gauge, each tool being cylindrical and having an axial dimension extending along an axis of rotation and a circumferential dimension extending orthogonally to the axial dimension, each tool having rows of teeth extending from the circumferential surface, each tooth having a rounded sheet engaging surface and each tooth having; a rounded peak;a first radius extending along a first direction;a second radius extending along the axial dimension;a third radius extending in a third direction orthogonal to the first direction,said first and third directions extending between said axial and circumferential dimensions, said third radius being equal to a radius of curvature at and adjacent the peak of each tooth, the second radius being the same as the third radius, and the pitch between adjacent teeth in a row being at least three times said radius of curvature, said radius of curvature and pitch providing a balance between maximizing work hardening and minimizing sheet material thinning, the tools being located in close proximity such that teeth on one tool extend into spaces between the teeth of the other tool and the tools being mutually counter-rotatable such that successive teeth on one tool move into and out of alignment with the space between adjacent teeth of the other roll and wherein the rolls are spaced such that each apex of a projection formed on a sheet by action of a tooth of one roll as the sheet passes between the tools is free from contact with the other roll for cold forming sheet steel material. 13. A sheet steel cold forming apparatus according to claim 12, wherein the pitch between adjacent teeth in a row on each tool is least 3.3 times said radius of curvature.
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