Apparatus and process for reducing profile variations in sheet metal stock

1. An apparatus for reducing profile variations in a sheet metal, comprising:

a first pass having first and second smoothing surfaces that are mateable to define a first profile between the first and second smoothing surfaces; and

a second pass having third and fourth smoothing surfaces that are mateable to define a second profile between the third and fourth smoothing surfaces, wherein the first profile is substantially the inverse of the second profile, the first smoothing surface is disposed adjacent to the second smoothing surface in a first direction, and the first pass is spaced apart from the second pass in a second direction away from the first direction.

2. The apparatus of claim 1 , wherein the third smoothing surface is disposed adjacent to the fourth smoothing surface in a third direction that is substantially parallel to the first direction.

3. The apparatus of claim 1 , wherein the first smoothing surface has surface features, the second smoothing surface has surface features, and the surface features of the first smoothing surface are substantially complementary to the surface features of the second smoothing surface.

4. The apparatus of claim 3 , wherein the third smoothing surface has surface features, the fourth smoothing surface has surface features, and the surface features of the third smoothing surface are substantially complementary to the surface features of the fourth smoothing surface.

5. The apparatus of claim 4 , wherein the surface features of the third smoothing surface are substantially complementary to the surface features of the first smoothing surface.

6. The apparatus of claim 5 , wherein the surface features of the fourth smoothing surface are substantially complementary to the surface features of the second smoothing surface.

7. An apparatus for reducing profile variations in roll stock, comprising:

a first pass including a first roll and a second roll, the first roll and the second roll each having surface features, such that the surface features of the first roll are substantially complementary to the surface features of the second roll; and

a second pass including a third roll and a fourth roll, the third roll and the fourth roll each having surface features, such that the surface features of the third roll are substantially complementary to the surface features of the fourth roll, wherein the surface features of the third roll are complementary to the surface features of the first roll, the first roll is disposed adjacent to the second roll in a first direction, and the first pass is spaced apart from the second pass in a second direction away from the first direction.

8. The apparatus of claim 7 , wherein the first roll, the second roll, the third roll, and the fourth roll are corrugated.

9. A method of reducing surface variations in a roll stock having a width, the method comprising:

deforming the roll stock in a first direction at a first plurality of locations that are spaced apart along the width of the roll stock; and

deforming the roll stock in a second direction at the first plurality of locations, wherein the first direction is substantially opposite from the second direction.

10. The method of claim 9 , wherein the step of deforming the roll stock in a first direction at a first plurality of locations further comprises substantially contemporaneously deforming the roll stock in the second direction at a second plurality of locations that are spaced apart along the width of the roll stock.

11. The method of claim 10 , wherein the step of deforming the roll stock in a second direction at the first plurality of locations further comprises substantially contemporaneously deforming the roll stock in the first direction at the second plurality of locations.

12. The method of claim 10 , wherein each location in the first plurality of locations is adjacent at least one of the locations in the second plurality of locations.

13. The method of claim 9 , wherein the step of deforming the roll stock in a first direction at a first plurality of locations comprises passing the roll stock between a first corrugated roll and a second corrugated roll.

14. The method of claim 13 , wherein the step of deforming the roll stock in a second direction at the first plurality of locations comprises passing the roll stock between a third corrugated roll and a fourth corrugated roll.

15. A method for reducing profile variations in a sheet metal stock, comprising:

providing a sheet metal;

forming the sheet metal in the shape of a first profile; and

forming the sheet metal in the shape of a second profile, wherein the first profile and the second profile are substantial inverses of one another.

16. The method of claim 15 , wherein the step of forming the sheet metal in the shape of a first profile comprises passing the sheet metal through first and second smoothing surfaces, wherein the first profile is defined between the first and second smoothing surfaces.

17. The method of claim 16 , wherein the step of forming the sheet metal in the shape of a second profile comprises passing the sheet metal through third and fourth smoothing surfaces, wherein the second profile is defined between the third and fourth smoothing surfaces.

18. The method of claim 16 , wherein the first smoothing surface is defined on a first roll, and the second smoothing surface is defined on a second roll.

19. The method of claim 16 , wherein the first smoothing surface is defined on an upper die platen, and the second smoothing surface is defined on a lower die platen.