ROLL-FORMED AUTOMOTIVE BUMPER AND METHOD OF MAKING SAME

Abstract: A bumper bar (1) for vehicles is formed from rolled sheet steel (S) having a closed tubular profile with a longitudinal weld (13) between abutting edges of the sheet and designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive designs. Apparatus to produce the bar includes first rollers (23-29) which form an indentation in the tube and second rollers (29A,29B) which engage the indentation to advance the tube in the sweep forming means (33), the sweep-forming means including a series of short mandrels (34a,34b) carried by supporting means (41,42) supported from an anchoring structure (43).

Description: This invention relates to automotive bumper bars, and more specifically a roll-formed tubular bumper made of high strength sheet steel of less than 2.54 mm (.100 inch) thickness with a high impact resistance, low weight, and relatively low cost of manufacture. Automotive bumpers are subject to a variety of design requirements due to consumer demands, government regulation, and the competitiveness of the industry. Bumpers must maintain a high level of strength and damage resistance to meet consumer expectation and government regulation concerning low speed vehicular impact. However, a bumper must also be of low weight to minimise vehicular dead weight which reduces fuel consumption and increases suspension requirements. Also, bumpers must have a low manufacturing cost and high dimensional consistency given the competitiveness of the industry. Thus, high strength-to-weight ratios and ease of manufacture are critical to the success of bumper systems. These requirements are further complicated by the present aerodynamic design trends which call for a high degree of sweep across the front of automobiles, such sweep also contributing to the strength of the bumper and its spring-back characteristics. A variety of designs and methods have been tried to improve bumpers. Many have used new metallic materials (such as aluminium or heat treatable steel alloys) and engineering resins (such as urethanes and elastomers) with varying degrees of success. However, many of these new materials suffer from availability and cost problems as well as special processing problems. In addition, where combinations of materials are used, assembly time is increased. Further, the automotive industry continues to demand even higher strength-to-weight ratios. A conventional bumper has a C-shape formed of relatively low strength and thick steel. Many of such C-shaped bumpers are roll-formed (see for example DD-A-146 794) and some are formed with a sweep at the end of the roll-forming operation by passing them over mandrels. A problem of the traditional, predominant, "C" section bumper is the sudden collapse experienced during deflection when the horizontal flanges give way. The sudden failure makes it more difficult to properly trigger the inflation of air bags which are intended to cushion passengers from secondary impacts during a vehicle crash. Lastly, bumper attachment methods have become more critical as bumper strengths increase. Forces of impact are larger and transferred more directly. Thus, it is an intention of this invention to greatly improve strength and reduce weight over present bumper systems while utilising available materials in a reliable and cost-efficient process of manufacture. It is a further intention of this invention to provide a bumper which provides its strength and impact resistance over an extended deflection cycle without experiencing the sudden failure experienced by the prevalent traditional "C" section bumpers. It is also an intention of this invention to provide a method of manufacture allowing a high degree of sweep along the longitudinal length of the bumper, thus allowing for designs which meet the highly aerodynamic designs called for by modern trends and also producing a stronger bumper with improved spring-back characteristics. It is also an intention of this invention to provide a unique attachment means which will meet the requirements of such a high strength bumper. To these ends, the present invention provides an automotive bumper bar and a method of and apparatus for making such bumper as disclosed in the independent claims 1, 2, 10 22 and 31. According to one aspect of the present invention, a bumper bar for a vehicle comprises a formed sheet of high tensile strength steel of at least 413.7 MPa (60 KSI) and less than 2.54 mm (.100 inch) thickness, the formed sheet having side edges and being roll-formed to cause the side edges of the sheet to abut one another, the side edges being connected together by weld seam to form an integral tube. According to a second aspect of the invention, a method of forming a bumper bar for a vehicle comprises the steps of roll-forming a sheet of high tensile strength steel having side edges to cause the side edges to abut one another and welding the side edges together to form an integral tube. According to a third aspect of the invention, apparatus for making bumpers comprises a means for roll-forming a sheet of high tensile strength steel having side edges to cause the side edges to abut one another, a means for welding the side edges together to form an integral tube, and a means for forming a sweep in the integral tube. The bumper may be made from a variety of high strength steels of varying thickness and rolled into a variety of tubular cross-sectional shapes. The invention solves the aforementioned problems by roll-forming a closed tubular cross section from high strength sheet steel, for example steel of at least 413.7 MPa (60 KSI) and 2.54 mm (.100 inches) maximum thickness. By forming a closed section, the strength of the bar is greatly increased. This allows weight reduction by use of a reduced material thickness. The closed design also improves deflection curves by avoiding the sudden collapse experienced by traditional "C" section bumpers as the flanges give way. A narrower but important aspect of this invention is the formation of a sweep during the roll-forming process. This sweep allows for manufacture of a bumper which will satisfy modern aerodynamic designs and also increase the strength of the bumper and improve its spring-back characteristics. A still narrower aspect of this invention allows for formation of an attachment surface capable of withstanding the force created by an impact upon the bumper. The invention may be carried into practice in various ways but an example of a bumper, methods of making those bumpers and apparatus for use in the methods, all in accordance with the present invention, will now be described by way of example with reference to the accompanying drawings, in which: Fig. 1 is a front view of a roll-formed bumper, Fig. 2 is a plan view of the roll-formed bumper with a sweep; Fig. 2A is an enlarged portion of the plan view of Fig. 2; Fig. 3 is a cross-sectional view of the bumper in Fig. 1 taken along the plane III-III; Fig. 4 is a schematic view of roll form apparatus for practising the methods of the invention; Fig. 5 is a sketch illustrating the method employed to measure sweep; Fig. 6 is a perspective, cross-sectional view taken along the plane VI-VI of Fig. 4; Fig. 7 is a cross-sectional view taken along the plane VII-VII of Fig. 6; Fig. 8 is a perspective, cross-sectional view taken along the plane VIII-VIII of Fig. 4; Fig. 9 is a cross-sectional view taken along the plane IX-IX of Fig. 4; Fig. 10 is a cut-away, schematic view of a side of the sweeping means showing the sweeping mandrels and anchoring rod; Fig. 11 is a frontal view of the sweeping station disclosing the mandrels which form the curvature in the bumper; Fig. 12 is a schematic view of a section of the roll-form apparatus illustrating the position of a mandrel at the last two rollers; Fig. 13 is a view of the back of a modified end of the bumper; Fig. 14 is a plan view of the modified end of the bumper illustrating the attachment of the same to a support on a vehicle; and Fig. 15 is a partial, perspective view of the end of the bumper as disclosed in Figs. 13 and 14. A bumper bar 1 in accordance with this invention is shown in Figs. 1, 2, 2A and 3 and has a front side 2, rear side 3, top side 4, and bottom side 5. Front side 2 includes an indentation 6 having an upper ledge 7, lower ledge 8, and central portion 9. Rear side 3 also includes an indentation 10 composed of an upper edge 11 and lower edge 12. Indentations 6 and 10 are provided for two reasons. Indentations 6 and 10 contribute to and thus increase the strength of the bumper 1 and also provide the unique function of contributing to the movement of the bumper over the sweep forming mandrel as will be explained hereinafter. Bumper bar 1 is constructed of a sheet of high strength steel roll-formed to cause its edges to abut one another. The edges are permanently induction welded by a welded seam 13. The bumper is roll-formed by apparatus schematically depicted in Fig. 4 using traditional components of a roll-forming apparatus 20 uniquely modified as will be described hereinafter to produce an unusually high radius sweep as shown in Fig. 2. Sweep, as used in the automotive industry, is the term utilised to describe the curvature of the bumper. Measurement of sweep may be derived from charts such as shown below which include the measurements of the distance from a vertical plane "P" located at the forwardmost point of the bumper and perpendicular to the longitudinal axis of the car to various points along the bumper as disclosed in Fig. 5. As the following chart refers to a practical example which is expressed in inches no conversion has been made. It may be converted to metric dimensions by using the conversion factor: 1 inch equals 25.4 mm. Referring to the above chart and Fig. 5, the relative position of various points can easily be determined. For example, in a No. 5 sweep (i.e. a curvature having a 720'' radius), point A which is 30.0'' from longitudinal centreline (C/L) of the car is .625'' (the distance "d") rearward of the front plant "P" of the bumper. Similarly, in a No. 60 sweep (i.e. curvature having a 63.75'' radius), point A is 7.500'' (the distance "d") rearward of the front plane "P" of the bumper. The sweep on present day bumpers has been extremely limited by the structural design of such bumpers and the methods and apparatus of manufacturing the same. As a result, the sweep generally has been below 30 sweep. Bumpers constructed in accordance with this invention has fallen within the range of 30-60 sweep which was unheard of in the automotive industry. Although bumper bar 1 is formed from a sheet of high strength steel, the specific grade and type of high strength steel may vary within a range of parameters depending upon the specific application in question. This range includes two specific parameters which in accordance with narrow aspects of this invention are important to the invention; specifically, the tensile strength generally measured in units of MPa or KSI (thousand pounds of force per square inch) and thickness generally measured in the thousandths of an inch or in millimetres (mm). In accordance with the more narrow aspects of this invention, the tensile strength range of presently available steel is from 413.7 to 827.4 MPa (60 to 120 KSI) although higher strength steels might be used as they may become available, it being understood therefore that the KSI range must be at least 413.7 MPa. The thickness range is from 1.22 to 2.54 mm (.048 to .100 inches), it also being understood that if higher strength steels above 827.4 MPa (120 KSI) become available, the thickness may be even less than 1.22 mm (.048 inches). In any event, to obtain the maximum advantage of the invention, the thickness must be less than 2.54 mm (.100 inches). Bumpers have been successfully formed by this invention from steel ordered pursuant to ASTM A606-85 and ASTM A715-87 designations more specifically discussed hereinafter. However, experience suggests that the materials need not be limited to these two materials. Use of even higher strength materials such as Martinsite (an ultra high strength material of 1035 to 1380 MPa (150-200 KSI) is contemplated. It should be noted that "ASTM" is a commonly recognised abbreviation for the American Society for Testing and Materials, and the suffix "85" means that the standard was re-approved in 1985 by the ASTM committee having jurisdiction over this standard. Details on ASTM specifications and designations are available through the ASTM society, as is widely known in the industry. Therefore, only cursory information is included hereinafter. "ASTM A606-85" is an ASTM designation calling for a high-strength, low alloy, rolled steel with improved atmospheric corrosion resistance and a tensile strength of up to approximately 482.5 MPa (70 KSI). The material is intended for structural use where savings in weight and added durability are important. Various "types" may be ordered such as "Type 4", for instance, which has four times the corrosion resistance of plain carbon steel. Various ordering information is required such as type of rolling (hot or cold rolled), dimensions (height, width, thickness), special requirement, and etc. The chemical composition is varied by the steel manufacturer to meet specific strength and formability requirements of the user. "ASTM A715-87" is an ASTM designation calling for a high-strength, low alloy, rolled steel with improved formability over ASTM A606 materials. The steel is killed to form fine grain steel and includes various combinations of special micro-alloying elements such as columbium, titanium, vanadium, zirconium, and other elements. ASTM A715 offers improved formability as well as improved weldability, and may include tensile strengths of up to 620 MPa (90 KSI). The inventor has also utilised AISI 050WK and AISI 120XF materials successfully. "AISI" is a commonly recognised abbreviation in the industry for the American Iron and Steel Institute. AISI specifications are typically cross-referenced to the most similar ASTM designation, but contain a slightly different classification scheme. For example, AISI 050WK refers to ASTM A606-85 with the "050" standing for minimum tensile yield strength (in KSI), the "W" for weatherability, and the "K" for the fact that the steel is killed. AISI 120XF has no ASTM reference at present, but is similar to ASTM A715-87 in that AISI 120XF has a high minimum yield strength (120 KSI minimum), is low alloy ("X"), and killed plus inclusion control ("F"). AISI 120XF may or may not be supplied as a G60 minimum spangle galvanised sheet. As noted, within the above ranges the specific type and grade of high strength steel may vary depending on the application. The material thickness, chemical composition, and tensile strength all affect cross-sectional formability and the ability to form a sweep. The inventor has successfully formed steel having a 1.83 mm (.072") thickness and a tensile strength of 552-827.5 MPa (80-120 KSI) to a No. 40 sweep from the above materials. Steel having a 1.83 mm (.072") thickness and a tensile strength of 552 MPa (80 KSI) has successfully been formed to a No. 60 sweep. However, by experience, we have discovered that in the use of a steel having manganese, a maximum manganese content of 1.2 percent (1.2%) is preferred in the process of this invention in that a steel with greater manganese content resulted in a problem of "shelving". Shelving is a problem which may be experienced in roll-forming wherein the steel will separate into laminate "shelves" due to the high shear and stress of forming. Shelving is undesirable since it results in material separation and greatly reduces a bumper bar's strength and reliability. Fig. 4 is schematic showing an example of apparatus for forming the bumper bar 1 and thus illustrates the process in producing the bumper bar. In Fig. 4 reference numeral 20 designates the overall apparatus which starting from the left side of the figure includes a steel roll holder 21 which rotatably supports a steel roll 22 which contains a flat strip S of steel as described above and which extends into a series of roller assemblies 23, 24, 25, 26, 27, 28, 29, 29A and 29B. These rollers have a shape that as the strip is passed therethrough the strip of steel is gradually formed into the form shown in Fig. 3. Although nine such roller assemblies have been shown for illustration purposes only, the number can be substantially increased and for some shapes may actually be decreased. Near the end of the apparatus 20 is an induction welder 30 of any well known type that will weld the two edges 31 and 32 together after such edges are caused to abut each other as shown in Fig. 9. In welding the abutting edges the induction welder 30 generates substantial local heat in the area of the tube near the weld which assists in the sweeping of the tube as will now be described. Means is provided downstream of the induction welder 30 for producing the sweep (sweeping) of the bumper bar 1 as shown in Fig. 2. This sweep producing or sweeping means shown in Figs. 4, 10 and 11, comprises a sweeping box 33 which includes a series of pairs of internal and external mandrels (34a and 35a, 34b and 35b, etc.) between which the tube formed by the rollers 23-29b and induction welder 30 pass. These mandrels have rounded ends as shown to assist in guiding the tube 1 between them. Each external mandrel is held by a mandrel frame 36 (Fig. 11) which is anchored at a horizontal centrepoint by a stabiliser 37. The sweep of the tube may be increased by vertical adjustments of the sweep adjusters 38a, 38b, 38c, etc. For example, as sweep adjuster 38a is adjusted upward, stabiliser 37a is also raised, thus forcing mandrel frame 36a and external mandrel 35a upward. Obviously, internal mandrel 34a is forced to follow this movement since the cross-sectional shape of the internal mandrels 34 are substantially identical to the cross section of the bumper 1. Therefore, as the roller formed tube passes thereover, it assumes the curvature or sweep of the mandrels. The internal mandrels are supported by a support assembly (Fig. 6) which includes two rods 41 and 42 extending from and secured to a support 43. The location of support 43 is selected to a position where the support 43 can extend downwardly into the tube as illustrated by Fig. 6. At this position, the steel strip has been rolled to form the front side 2 and the two top and bottom sides 4 and 5 and wherein the back side has not yet been formed leaving an opening 14 though which the support 43 extends. It should be understood as the steel strip continues to pass through the rollers 27, 28 and 29 downstream of the support 40, it is progressively formed by the rollers 27, 28 and 29 to the shape shown in Fig. 8. Fig. 9 shows the shape of the tube roller formed to the desired shape with the edges 31 and 32 abutting. As the tube thus formed passes through the induction welder 30, the edges 31 an 32 are welded together. The tube then continues through rollers 29a and 29b which push against an internal mandrel 29c (Figs. 9 and 12) which is similar in shape to the inside cross section of bumper bar 1 (Fig. 9). This allows rollers 29a and 29b to generate sufficient force to force bumper bar 1 forward across the sweeping box 33 without crushing or deforming the cross section of bumper bar 1. As previously referred to, the indentation in the front side 2 of the bumper bar 1 is provided for two reasons. It gives additional strength to the bumper 1 and also provides a means for moving the bumper tube over the mandrels 34, 35 and 36. As illustrated in Fig. 9, the indentation 6 includes the ledges 7 and 8 which are engaged by the projecting sides 45 and 46 extending radially outwardly from roller 29b. Also, indentation 10 includes ledges 11 and 12 engaged by projecting sides 47 and 48 extending radially outwardly from rollers 29b. This engagement between the edges formed by ledge 7 and side 45, ledge 8 and side 46, ledge 11 and side 47 and ledge 12 and side 48 of the roller assembly 29b, and any of the other roller assemblies upstream thereof wherein the indentations 6 and 10 have already been formed, drives the bumper bar 1 over the mandrels 34 and 35 in sweep box 33. This driving force also is created by roller 29a. As shown in Fig. 4 there is a cut-off apparatus 50 downstream of the mandrels 34 and 35 for cutting off the bumper bar 1 at its proper length. The bumper bar 1 that has thus been cut off is ready for further operations such as providing an attachment means for attaching the bumper bar 1 to the vehicle. Operation Having described the apparatus 20 and the bumper bar 1 that is formed thereby, the operation of the apparatus 20 and the uniqueness of the bumper bar 1 is evident. The steel strip S payed off from the roll 22 passes through the roll assemblies to form the tube as shown in Fig. 9 with the edges 31 and 32 of the steel strip abutting each other. The induction welder 30 forms the welded seam 13 to form a unitary integral tube 13 as disclosed in Fig. 10, the tube thus formed being straight. It is within the contemplation of the broader aspects of this invention that the tube thus formed can be utilised as a straight bumper bar having substantial improved characteristics. It has a substantially higher level of strength and damage resistance so as to meet consumer expectation and government regulation concerning low speed vehicular impact. It has also low weight to minimise vehicular dead weight and low manufacturing costs. The high strength-to-weight ratio and ease of manufacture contribute to the superiority of the bumper. Such superiority is made possible by forming the bumper of a high-strength sheet steel, with lower than normal thickness, roll-formed as described above. In accordance with the preferred more narrow aspects of this invention, the tube formed by the roller assemblies 23-29 and welder 30 is curved or sweeped to produce a bumper having a sweep of from 0-60. The higher the sweep, the stronger the bumper and the more spring back of the bumper. Such curvature or sweep is produced by passing the tube from the induction welder over the curved mandrel pairs 34 and 35, it being understood that one or more mandrels can be used. The tube is passed over the mandrels immediately after the weld seam 13 is produced by the induction welder 30. Thus, the steel is still in a locally heated condition which assists in the ease of curving or sweeping the tube without adversely affecting the structure. After the sweep is formed, the bumper bar 1 is cut off by the cut off apparatus 50 (Fig. 4). The sweeping of the tube after it leaves the welder 30 is made possible by the unique support assembly 40 (Figs. 6 and 7) located upstream of several of the roller assemblies so that the support 43 can extend through the opening 14 and into the tube so as to support the mandrels downstream by means of the rods 41 and 42. The driving of bumper bar 1 through the sweeping box 33 as is made possible by the rollers 29a and 29b and indentations 6 and 10, the configurations of which generate sufficient force to force bumper bar 1 through sweeping box 33. Modification The present roll-formed bumper as described above makes possible a novel means for supporting the bumper on the vehicle. Figs. 13 and 14 show such means which includes the ends of the bumper 1 being crushed and deformed to provide a flat surface 51 to which securement means such as a bolt 52 (Fig. 13) can be attached for mounting the bumper bar 1 to a flat surface on a support such as a bracket 53 extending from the vehicle. More specifically, as shown in Figs. 13, 14 and 15, the flat surface 51 and its orientation with respect to the support bracket 53 is provided by the crushed or deformed outer ends of the bumper. As best seen in Fig. 15, the rear side 3 is inclined to the front side 2 thereby causing the collapsed portions 4a and 5a of sides 4 and 5. Collapsed side portions 4a and 5a provide the inclined flat surface 51 with a predetermined orientation allowing the surface 51 located on the plane P-P (Fig. 14) to mateably butt against a bracket 53 extending from the vehicle. A hole 54 is provided at each end (only one end is shown) and extends through the front side 2, rear side 3 and surface 51 and receives attachment bolt 52. The deformed end of the bumper 1 and the bolt 52 thereby form a structure for attachment of the bumper bar 1 to a part of the vehicle such as the bracket 53.

Claims: An automotive bumper bar (1) for mounting at an end of a vehicle for resisting damage to the vehicle upon the vehicle impacting with an object in a direction along the longitudinal centreline axis of the vehicle comprising a formed sheet (S) of high tensile strength steel of at least 413.7 MPa (60 KSI) and less than 2.54 mm (.100 inch) thickness, the formed sheet having side edges (11,12) and being roll-formed to cause the side edges of the sheet to abut one another, the side edges being connected together by a weld seam (13) to form an integral tube having a front wall and a rear wall connected together by sidewalls. An automotive bumper bar (1) for mounting at an end of a vehicle for resisting damage to the vehicle upon the vehicle impacting with an object in a direction along the longitudinal centerline axis of the vehicle comprising a sheet (S) of high tensile strength steel having a thickness of less than 2.54 mm (.100 inch), roll-formed substantially to form a tube, the said tensile strength being at least 413.7 MPa (60 KSI), the tube having a sweep and having front and rear walls (2,3) connected together by sidewalls (4,5), the side walls being connected by a weld seam and the front wall (2) being shaped to provide means for rollers-to engage and advance the tube when the sweep is formed therein. A bumper bar according to Claim 2 in which the rear wall (3) is also shaped to provide ledges (7,8) for rollers to engage and advance the tube when the sweep is formed therein. A bumper bar according to any of claims 1 to 3 wherein the tube has a sweep in a direction away from the front wall. A bumper bar according to any of claims 2 to 4 wherein the tube has at least a No. 30 sweep. A bumper bar according to Claim 4 or Claim 5 in which the edges which are welded together are located in the rear wall and in which the tube has an indentation (6) in the front wall providing means for rollers to advance the tube when the sweep is formed. A bumper bar according to any preceding claim wherein the said high strength steel has a maximum manganese content of 1.2%. A bumper bar according to any preceding claim wherein the ends of the bar are deformed to provide a structure (51) for attachment. A bumper bar as claimed in Claim 8 wherein the end portions of the sidewalls (4,5) and the end portions of the rear wall (3) are deformed such that the said end portions of the rear wall (3) provide a substantially flat surface for attachment to the vehicle. Apparatus for making bumpers characterised by a means (20) for roll-forming a sheet (S) of high tensile strength steel having side edges (11,12) to cause the side edges to abut one another, a means (30) for welding the side edges together to form an integral tube having a front wall, a rear wall, and side walls connecting the front and rear walls, and a means (33) for forming a sweep in the integral tube in a direction away from the front wall. Apparatus according to Claim 10 in which the roll forming means (20) includes a first roller means (23-29) for forming the tube, and being adapted to form ledges (7,8) in at least one of the front or rear walls of the tube for engagement by rollers to advance the tube, second roller means (29A,29B) downstream of the first roller means and upstream of the means for forming a sweep, the second roller means being shaped to extend into and engage at least portions of the ledges (7,8) in one of the walls of the tube, the shape of the second rollers for engaging at least portions of the ledges being adapted to advance the tube in the means for forming a sweep. Apparatus according to Claim 10 in which the roll forming means (20) includes first roller means (23-29) for forming the tube; elongated support means extending a distance upstream of the welding means (30) to a position wherein the side edges are spaced one from the other, the elongated support means (41,42) supporting the means (33) for forming a sweep in the integral tube; an anchoring structure (43) supporting the elongated support means at the said position, the first roller means (23-29) being located upstream of the means for forming the sweep and shaped to form ledges (7,8) in one of the front or rear walls of the tube; and second roller means (29A, 29B) located downstream of the first roller means (23-29) and shaped to engage at least portions of the ledges to thereby advance the tube into the means for forming a sweep. Apparatus according to Claim 10 in which the roll-forming means (20) includes first roller means (23-20) for forming the tube,said means for welding being an induction welder, located upstream of the means for forming a sweep in the integral tube, which generates heat in the tube which assists the sweep forming means in forming the sweep, the first rollers being located upstream of the means for forming a sweep and shaped to form ledges in at least one of the front or rear walls of the tube; and second roller means (29A,29B) shaped for engaging at least portions of the ledges to thereby advance the tube into the means for forming a sweep. Apparatus according to Claim 10 in which the means for forming a sweep includes mandrel means (34) adapted to be received within a tube formed by the roller means; the apparatus further including an elongated support means (41,42) adapted to extend inside a tube, formed by said roller means, a distance upstream of the welding means (30) to a position wherein the side edges are spaced one from the other; the elongated support means supporting the mandrel means in the integral tube and an anchoring structure (43) supporting the elongated support means at the said position, and the mandrel means (34) including a series of short mandrels spaced but connected together. Apparatus according to Claim 10 in which the sweep forming means includes curved external mandrel means (35) and curved internal mandrel means (34); the apparatus further comprising support means (41,42) for supporting the internal and external mandrel means in relatively stationary spaced relationship one from the other to provide a passageway therebetween for receiving the integral tube therebetween, the support means including an elongated member (41,42) attached to the internal mandrel means (34) and extending therefrom to a support member (43) extending through an opening located upstream of the sweep forming means (33) where the side edges of the sheet are not abutting; means for causing the integral tube to pass through the passageway while the roll-forming of the sheet upstream of the external and internal mandrel means takes place and the upstream sheet connected to the integral tube is being roll-formed, the internal and external mandrel means being adapted when the tube is passed through the passageway to produce a predetermined sweep in the tube as determined by the shape of the passageway; and cutting means (50) located downstream of the sweep forming means (33) for cutting the swept integral tube at predetermined lengths whereby a series of bumper bars can be continuously formed in succession during the roll-forming of the sheet upstream of the sweep forming means. Apparatus according to Claim 15 in which the internal mandrel means (34) and external mandrel means (35) include a series of short mandrels spaced from each other but connected together. Apparatus according to Claim 10, Claim 15 or Claim 16 in which the roll-forming means (20) includes a first roller (23-29) for forming the tube and a second roller (29A,29B) for gripping the tube and forcing it through the sweep forming means (33). Apparatus according to Claim 10 or Claim 17 in which the first roller means (23-29) is shaped to form ledges (7,8) in at least one of the front or rear walls of the tube and the second roller means (29A,29B) is shaped to extend into and engage at least portions of the ledges, the shape of the second rollers engaging at least portions of the ledges to advance the tube in the means for forming a sweep (37). Apparatus according to any of Claims 15 to 18 in which inner mandrel means is located at the second roller means whereby the tube is clamped between the second roller means (29A,29B) and a straight portion (29C) of the inner mandrel means for forcing the tube through the sweep forming means. Apparatus according to any of Claims 10 to 14 in which the means (33) for forming a sweep includes a mandrel means (34,35) over which the tube passes. Apparatus according to Claim 20 in which the mandrel means includes a series of short mandrels spaced but connected together. A method of forming a bumper bar for a vehicle characterised by the steps of continuously roll-forming a sheet (S) of high tensile strength steel having side edges (11,12) to cause the side edges to abut one another and welding the side edges together to form an integral tube. A method according to Claim 22 comprising: providing a sweep forming means having curved external mandrel means (35) and curved internal mandrel means (34) spaced from each other to provide a passageway therebetween for receiving the integral tube therebetween; passing the integral tube through the passageway while the roll-forming step upstream of the external and internal mandrel means takes place and the upstream sheet connected to the integral tube is being roll-formed, and during the said passing step continuously supporting the external and internal mandrel means in stationary positions, the internal means being supported by support means having an elongated member (41,42) extending from the internal mandrel means to a support member (43), the support member being located upstream of the sweep forming means (33) where the side edges of the strip are not abutting thereby providing an opening through which the support member (43) extends for attachment to the elongated member; the step of passing the tube through the passageway producing a sweep in the tube as determined by the shape of the passageway; and cutting the swept integral tube into lengths after the sweeping of the tube has been completed to continuously form in succession a series of bumper bars during the roll-forming of the sheet upstream of the sweep forming means. A method according to Claim 22 or Claim 23 in which the strip of steel has a thickness less than 2.54 mm (.100 inch) and a tensile strength of at least 413.7 MPa (60 KSI). A method according to any of Claims 22 to 24 in which the welding step is accomplished by induction welding to heat the formed tube portions prior to the sweep forming step whereby the heating of the formed tube portions assists in the sweeping of the tube portions. A method according to any of Claims 22 to 25 in which the steel strip provided has a maximum manganese content of 1.2 % and/or the bar is given a sweep of greater than No. 30 sweep. A method according to any one of Claims 22 to 26 in which a straight internal mandrel is provided upstream of the curved internal (34) and external (35) mandrels, and prior to forming the sweep and after the two portions of the strip are formed into the integral tube, passing the integral tube over the said straight mandrel (29C), and causing the roller means to engage and act on the integral tube located between the roller means and straight mandrel (29C) whereby the said formed portions are caused to be advanced to and through the sweep forming means. A method according to Claim 27 in which the said straight mandrel (29C) is also supported by the said support means (41,42). A method according to any one of Claims 22 to 28 in which the sheet is roll-formed by rollers producing two portions with front and rear walls connected together by sidewalls, at least one of the walls being formed with ledges (7,8), the roller means being shaped for engaging at least a portion of the ledges to increase the gripping of the integral tube by the roller means when passing over the straight mandrel (29C). A method according to Claim 29 in which the rollers have protrusions (42,46,47,48) for engaging the ledges (7,8), and the walls of the indentation are engaged with the protrusions and the tube is advanced through the sweep forming means by means of the said engagement. A method of forming a bumper bar for a vehicle comprising the steps of providing a first roller means (23-29) adapted to form a tube with front and rear walls, one of said walls having ledges (7,8); providing a sheet of high tensile strength steel having side edges and continuously passing the sheet through the first roller means (23-29) to cause a tube to be formed with side edges abutting one another; welding the edges together to form an integral tube; providing a sweep forming means (33) for forming a sweep in the tube; providing a second roller means (29A,29B) upstream of the sweep forming means, the second roller means shaped to extend into and engage at least portions of the ledges (7,8) in the tube formed by the first roller means, causing the second roller means to engage the ledges of the tube; and driving the second roller means to cause the tube to be forced through the sweep forming means thereby forming a sweep in the integral tube.

Inventors: HEINZ, RICHARD DAVID, STURRUS, PETER
Applicants: SHAPE CORPORATION
Application year: 1991
Main classification: B60R19
IPC codes: B21H8, B21D53, B60R19