Device and method for leveling a metal plate

1. A device configured to level a metal plate fabricated from high-strength metal material, the device comprising:

a frame;

a leveling station including one pair of upper rollers and a corresponding one pair of lower rollers rotatably disposed on the frame in a parallel arrangement in a lateral direction and defining a serpentine path that is disposed in a longitudinal direction that is associated with a direction of travel for the metal plate; and

wherein each one of the one pair of upper rollers includes a cylindrical outer peripheral surface that extends in the lateral direction and radially surrounds an upper axis of rotation;

wherein each one of the one pair of lower rollers includes a cylindrical outer peripheral surface that extends in the lateral direction and radially surrounds a lower axis of rotation;

wherein the radii of each one of the one pair of upper rollers and the radii of each one of the one pair of lower rollers are equivalent;

wherein the upper axes of rotation are offset in the longitudinal direction from the lower axes of rotation such that a longitudinal spacing is defined between the axes of rotation of contiguous ones of the one pair of upper rollers and the one pair of lower rollers;

wherein a plunge depth is defined as a difference in an elevation direction between a first elevation associated with a top-dead-center point of each one of the one pair of lower rollers and a second elevation that is associated with a bottom-dead-center point of each one of the one pair of upper rollers;

wherein the magnitude of the plunge depth associated with each one of the one pair of upper rollers and one of the one pair of lower rollers that is longitudinally disposed between the one pair of upper rollers is equal to the magnitude of the plunge depth associated with each one of the one pair of lower rollers and one of the one pair of upper rollers that is longitudinally disposed between the one pair of lower rollers;

wherein the serpentine path is defined between the outer peripheral surfaces of contiguous ones of the one pair of upper rollers and the one pair of lower rollers;

wherein the longitudinal spacing of each one of the one pair of upper rollers and each one of the one pair of lower rollers is equal to achieve the equal plastification on the first and second sides of the metal plate;

wherein the longitudinal spacing and the plunge depth are configured such that the one pair of upper rollers and the one of the one pair of lower rollers that is longitudinally disposed between the one pair of upper rollers imparts a first bend radius on the metal plate in a first orientation and the one pair of lower rollers and the one of the pair of upper rollers that is longitudinally disposed between the one pair of lower rollers subsequently imparts a second bend radius on the metal plate in a second orientation that is opposed to the first orientation as the metal plate moves through the serpentine path as the metal plate bends about a portion of the outer peripheral surfaces of each one of the one pair of upper rollers and each one of the one pair of lower rollers to subject the metal plate to plastic deformation corresponding to the portion of the respective outer peripheral surfaces of each one of the one pair of upper rollers and each one of the one pair of lower rollers to provide equal plastification on both sides of the metal plate;

wherein the magnitude of the first bend radius and the magnitude of the second bend radius is selected such that a magnitude of plastification of the metal plate that is greater than 70% is achieved once the metal plate moves along the serpentine path past the two upper rollers and the two lower rollers; and

wherein the magnitude of the first bend radius is equivalent to the magnitude of the second bend radius; and

wherein there is a quantity of not more than the one pair of upper rollers and a quantity of not more than the one pair of lower rollers to achieve equal plastification on both sides of the metal plate.

2. The device of claim 1 , wherein each bend radius is selected such that a magnitude of plastification of the metal plate that is greater than 90% is achieved once the metal plate moves along the serpentine path past the two upper rollers and the two lower rollers.

3. The device of claim 1 , wherein the bend radius is determined as a function of a modulus of elasticity of the material of the metal plate, a thickness of the metal plate, the magnitude of plastification of the metal plate, and a yield strength of the material of the metal plate.

4. The device of claim 3 , wherein each bend radius is determined as a function of a yield strength of the metal material of the metal plate being greater than 50,000 psi.

5. The device of claim 1 , wherein the longitudinal spacing, the upper rolling radii, lower rolling radii, and the plunge depth are configured such that as the metal plate moves through the serpentine path in the longitudinal direction, the pair of upper rollers impart a first bending stress on a first side of the metal plate and the pair of lower rollers impart a second bending stress on a second side of the metal plate, opposite the first side, such that the first and second bending stresses are equal to provide equal plastification on the first and second sides of the metal plate.