Integral embossing roller and manufacturing method thereof

Abstract

The present invention belongs to non-cutting metal machining, and in particular to embossing rollers. An integral embossing roller, the key point of which is that the roller consists of a central shaft and a bearing, the two ends of the central shaft are roller necks, the roller necks are used to install bearings, and the surface of the middle of the central shaft is processed with grooves, and multiple grooves are evenly spaced, and adjacent grooves are separated by cylindrical sections. The advantages of the present invention are simple and compact structure, more grooves can be arranged in the same length of working area, easy assembly, high yield rate of processed products, no pattern dislocation and torsional deformation; the integral mold has good rigidity and high strength, and compared with the sleeve-type combined roller, there is no time for changing the sleeve, which saves time; the roller can be reprocessed and reused after being worn; the integral roller can arrange more processing wires than the sleeve-type roller in the same axial size, so the integral roller has high production efficiency.

Description

Technical Field

[0001] The present invention belongs to metal machining without cutting; in particular, it belongs to embossing rollers. Background technology

[0003] like Figure 1-5 As shown in the figure, the roller is the main working part and tool on the rolling mill that causes continuous plastic deformation of the metal. It is mainly composed of three parts: the center shaft 1, the sleeve 3 and the bearing 2. Figure 1 As shown, a multi-section sleeve is sleeved outside the center shaft, and the center shaft and the sleeve are positioned and driven by a flat key 5. The sleeve is the middle part of the roller that actually participates in rolling metal. Grooves 31 are processed on the surface of the sleeve at intervals. The two ends of the grooves and between the two grooves are smooth cylindrical sections 32. Generally, a sleeve has two grooves. The two ends of the center shaft are roll necks 11 for installing bearings. The center shaft and the sleeve are assembled by mechanical processing, and the two ends are locked with nuts 7. Due to the machining error of the sleeve end face and the installation clearance, the sleeve is offset in the axial or circumferential (radial) direction of the center shaft. In the process of rolling metal wire, the upper and lower patterns of the product are misaligned, torsional deformation occurs, and the scrap rate is high. Figure 4 , 5 As shown, the side edge 311 of the rolling groove is perpendicular to the center line, and the profile is easy to slip when entering. The rollers can be arranged in the form of two rollers, three rollers, four rollers or multiple rollers in the rolling mill frame. Summary of the invention

[0004] The purpose of the present invention is to overcome the defects of the existing metal wire rolling process and provide an integral embossing roller which can better overcome the torsional deformation of metal rolling and the misalignment of upper and lower patterns to improve the yield rate.

[0005] The technical solution adopted by the present invention is an integral embossing roller, the key point of which is that the roller consists of two parts: a central shaft and a bearing. The two ends of the central shaft are roller necks, and the roller necks are used to install bearings. The surface of the middle part of the central shaft is processed with a groove, and multiple grooves are evenly distributed, and adjacent grooves are separated by cylindrical sections.

[0006] The present invention is an improvement on the existing technology. Structurally, the center shaft and the insert are combined into one, and the insert is eliminated. The nut is not required for fixing, and the groove is directly processed on the surface of the center shaft, so as to eliminate the matching gap and solve the defects of product pattern misalignment and torsional deformation. The two end surfaces of the existing insert are both cylindrical segments, and the spacing between the grooves of the two inserts is large, while the spacing between the two grooves in a single insert is short, and the spacing of the grooves is uneven. The spacing of the grooves of the present invention is uniform and the space is compact.

[0007] The pressing die processed on both sides of the groove is a convex die, the height of the convex die is greater than the designed pattern depth, and the height difference between the two is 5-10% of the designed pattern depth. The pressed pattern is clear.

[0008] The height of the punch is greater than the designed pattern depth, and the height difference between the two is 5-10% of the designed pattern depth.

[0009] The sides of the groove are inclined to both sides, forming a trumpet shape. The top of the groove is outward to facilitate extrusion guidance, and it is also a place for the excess material after extrusion to accommodate and reduce the internal stress of the material.

[0010] The angle between the side of the rolling groove and the center line of the roller body is 95°-100°.

[0011] The material of the center shaft is made of low-nickel ductile iron with infinite chilled cast iron alloy composition: C: 3.65%, Si: 1.65%, Mn: 0.96%, Ni: 0.81%, Cr: 0.91%, Mo: 0.39%, Re: 0.025%, Mg: 0.055%, P: 0.21%, S: 0.007%.

[0012] A method for manufacturing an integral embossing roller comprises the following steps: processing roller necks at both ends of a central shaft, processing a groove on the surface of the middle of the central shaft, and using a laser engraving machine to process a convex die for embossing a pattern on the surfaces of both sides of the groove. The height of the convex die is greater than the designed pattern depth, and the height difference between the two is 5-10% of the designed pattern depth.

[0013] The advantages of the present invention are simple and compact structure, more rolling grooves can be arranged in the same length of working area, and it is easy to assemble. 1) The finished product rate of the processed products is high, and pattern dislocation and torsional deformation will not occur; 2) The integral mold has good rigidity and high strength, and it is easy to ensure the stability of product quality; 3) Compared with the sleeve-mounted combined roller, there is no time for sleeve replacement, which saves time; 4) The roller mold can be reprocessed and reused when worn; 5) The integral roller has more processing wires than the sleeve-mounted roller in the same axial size (the sleeve is generally composed of multiple sections, and the corresponding number of processing wires is reduced), so the integral roller has high production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Schematic diagram of the structure of the existing roller

[0015] Figure 2 for Figure 1 BB cross-section view

[0016] Figure 3 for Figure 1 C enlarged view

[0017] Figure 4 for Figure 1 EE profile

[0018] Figure 5 for Figure 1FF cross-section

[0019] Figure 6 A schematic diagram of the structure of the present invention

[0020] Figure 7 for Figure 6 AA section view

[0021] Figure 8 for Figure 6 D enlarged image

[0022] Fig. 9 for Figure 6 GG profile

[0023] Fig.10 for Figure 6 HH profile

[0024] Among them: 1 center shaft 11 roll neck 2 bearing 3 sleeve 31 rolling groove 311 side 32 cylindrical section 4 punch 5 flat key 7 nut. DETAILED DESCRIPTION

[0025] The present invention is described in detail below in conjunction with the drawings. The embodiments listed can help those skilled in the art to better understand the present invention, but do not limit the present invention in any form.

[0026] like Figure 6-10 As shown, an integral embossing roller is improved on the basis of the prior art. The roller consists of a central shaft and a bearing. The two ends of the central shaft 1 are roller necks 11, and the roller necks are used to install bearings 2. The surface of the middle of the central shaft is processed with a rolling groove 31. Multiple rolling grooves are distributed at equal intervals, and adjacent rolling grooves are separated by cylindrical sections 32. The present invention combines the central shaft and the insert into one, improves it into an integrated type, eliminates the insert, flat key, and nut, and directly processes the rolling groove on the surface of the central shaft.

[0027] The pressing die for processing the two side surfaces of the rolling groove is a convex die 4, the height of the convex die is greater than the designed pattern depth, and the height difference between the two is 5-10% of the designed pattern depth. The pressed pattern is clear. The side edges 311 of the rolling groove are inclined to both sides, forming a trumpet shape. The angle between the two side edges of the rolling groove and the center line of the roller body is 95°-100°.

[0028] The material of the center shaft is made of low-nickel ductile iron with infinite chilled cast iron alloy composition: C: 3.65%, Si: 1.65%, Mn: 0.96%, Ni: 0.81%, Cr: 0.91%, Mo: 0.39%, Re: 0.025%, Mg: 0.055%, P: 0.21%, S: 0.007%.

[0029] A method for manufacturing an integral embossing roller comprises machining roller necks at both ends of a central shaft, machining a groove on the surface of the middle of the central shaft, and machining a convex die for embossing patterns on the surfaces of both sides of the groove using a laser engraving machine. The height of the convex die is greater than the designed pattern depth, and the height difference between the two is 5-10% of the designed pattern depth. In the embodiment, the diameter of the central shaft is 300 mm, and the groove depth is 13-20 mm. When the groove depth is less than 13 mm, the groove is machined, deepened to 20 mm, and reused. In this way, a roller mold can be reprocessed and reused at least 5 times when worn.

[0030] The remaining parts not described are the same as the prior art.

[0031] The above embodiments are only for illustrating the technical idea of ​​the present invention, and cannot be used to limit the protection scope of the present invention. Any improvement and equivalent replacement made on the basis of the technical solution in accordance with the technical idea proposed by the present invention shall fall within the protection scope of the present invention.

Claims

1. An integral embossing roller, characterized in that: The roller is composed of a central shaft and a bearing. The two ends of the central shaft are roller necks, which are used to install bearings. The surface of the middle part of the central shaft is processed with a rolling groove, and multiple rolling grooves are evenly spaced. Adjacent rolling grooves are separated by cylindrical segments. The manufacturing method is as follows: roller necks are processed at both ends of the central shaft, and rolling grooves are processed on the surface of the middle part of the central shaft. A laser engraving machine is used to process a convex die for pressing patterns on the surfaces of both sides of the rolling groove. The height of the convex die is greater than the designed pattern depth, and the height difference between the two is 5-10% of the designed pattern depth; the sides of the rolling groove are inclined to both sides and are trumpet-shaped; the material of the central shaft is low It is composed of nickel ductile iron with infinite chilled cast iron, and its alloy cast iron composition is: C: 3.65%, Si: 1.65%, Mn: 0.96%, Ni: 0.81%, Cr: 0.91%, Mo: 0.39%, Re: 0.025%, Mg: 0.055%, P: 0.21%, S: 0.007%; the diameter of the central axis is 300mm, the groove depth is 13-20mm, when the groove depth is less than 13mm, the groove will be processed, deepened to 20mm, and reused, so that a roller mold can be reprocessed and reused at least 5 times.

2. The integral embossing roller according to claim 1, characterized in that: The angle between the side of the rolling groove and the center line of the roller body is 95°-100°.

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