High performance metal sheet segmented power controlled roll forming device and method

Abstract

The application discloses a high-performance metal plate segmented variable-speed control rolling forming device and method, and belongs to the technical field of plate rolling forming. The device comprises three parts of a split roller (1), a whole roller (2) and a rolling mill base (3). The application adjusts the speed of the split roller by adjusting the planetary gear train, pushes the metal plate (4) into the roller for rolling, and obtains a high-performance rolling formed plate. The method innovatively changes the traditional roller from whole constant speed to independent speed adjustment of several split rollers, so that the plate is subjected to "bidirectional rolling deformation" along the width and thickness directions during rolling, and the depth improvement of the microstructure and performance of the plate is promoted. The method solves the problems of complex process flow and the need to increase passes during traditional rolling forming of high-performance metal plates. According to actual needs, the shape of the plate can be customized through independent regulation and control of the rotating speed of each split roller.

Description

Technical Field

[0001] This invention relates to a metal sheet rolling forming apparatus and method, specifically to a high-performance metal sheet forming apparatus and method for achieving variable speed rolling by independently adjustable split rolls, belonging to the field of sheet rolling forming technology. Background Technology

[0002] To meet the demands for high efficiency, green technology, and lightweight construction in aerospace, transportation, medical devices, and civilian manufacturing, the demand for lightweight thin-walled components has surged significantly. How to rapidly mass-produce high-quality sheet metal for these components has become a long-standing hot topic and challenge in this field, possessing significant engineering and practical value.

[0003] Casting, forging, extrusion, and rolling are all forming processes that can be used to manufacture sheet metal products. However, due to their inherent limitations, casting produces sheets with significant differences in grain morphology and poor microstructure uniformity, which deteriorates subsequent forming performance. Because sheet metal has flat and thin geometric characteristics, the required deformation is substantial, necessitating increased reduction and forging passes, and it is unsuitable for processing low-plasticity materials. Extrusion can form products with long, straight characteristics, but it is difficult to manufacture sheets with excessively large width-to-thickness ratios. In comparison, rolling is one of the ideal methods for mass production of thin-walled, wide sheet metal. However, traditional rolling processes for sheet metal manufacturing are complex, often requiring additional passes and prone to defects such as edge cracking. To further improve production efficiency and the quality and performance of sheet metal, new methods such as cumulative rolling, cross rolling, cast rolling, and liner rolling have emerged, achieving certain results and development in overcoming the bottlenecks of traditional rolling methods. Therefore, breaking through the constraints of traditional processes and developing new methods and processes is a long-term goal pursued in the field of high-performance sheet metal rolling manufacturing. Summary of the Invention

[0004] This invention proposes a high-performance segmented, variable-speed controlled rolling forming device and method for metal sheets. This method changes the roll structure and movement mode of traditional rolling processes, replacing the overall uniform speed of the rolls with several independently speed-controlled split rolls. Due to the different rotational speeds of each split roll, the stress state and deformation behavior of different parts of the sheet along the width and thickness directions during rolling are significantly different. The sheet is simultaneously subjected to interactive "bidirectional rolling deformation," i.e., twisting deformation, which promotes a deep improvement in the microstructure and properties of the sheet. Furthermore, the speed of each split roll can be precisely controlled individually according to actual needs, achieving quantitative and precise control over the microstructure, mechanical properties, and forming performance of the sheet.

[0005] This invention is achieved through the following technical solution: Step 1: Precisely control the speed of the split rolls using the meshing adjustment mechanism between the planetary gears and the sun gear. By adjusting parameters such as the radius and number of teeth of the sun gear and planetary gears, the wide-axis variable speed effect of the split rolls is achieved. Step Two: Surface Cleaning of the Metal Slab. First, clean the metal slab with acetone to remove impurities and contaminants. Then, thoroughly rinse the metal slab with anhydrous ethanol to ensure its surface is clean. Finally, allow the metal slab to air dry in preparation for subsequent processing. Step 3: Place the cleaned metal slab into the heating furnace for appropriate preheating. Set a suitable rolling temperature according to requirements and maintain the temperature for a period of time to allow the metal slab to acquire the necessary heat energy; Step 4: Adjust the rolling parameters according to the rolling requirements, including reduction and roll speed. The preheated metal slab is pushed between the rolls by pushers for rolling. By precisely controlling the rolling parameters, the deformation and thickness of the metal slab can be adjusted. Step 5: Perform necessary trimming and leveling operations on the rolled metal sheet, and trim the waste area as needed to meet actual requirements, so as to obtain the final metal sheet product that meets the requirements.

[0006] This invention is achieved through the following apparatus: This invention presents an innovative high-performance segmented variable-speed rolling forming device for metal sheets, which achieves variable-speed rotation of the rolls in the width direction. The device consists of three parts: a split roll 1, a continuous roll 2, and a mill stand 3. The split roll employs a planetary gear system, with speed input to the sun gear 12 via the main shaft 11, meshing with planetary gears 8 on the fixed shaft 9 to form the planetary gear system. Adjusting parameters such as the number of teeth on the sun gear 12, planetary gears 8, and the gear ring of the sleeve 10 changes the transmission ratio, thus achieving speed variation. Simultaneously, this device can achieve variable-speed control in both the width and thickness directions, enhancing the amount and complexity of twisting deformation received by the rolled metal sheet, resulting in a finer and more uniform microstructure. Furthermore, the frame structure ensures the overall operational stability and plays a crucial role in the roll movement.

[0007] This segmented, variable-speed controlled rolling forming device has the following advantages: 1. This device allows for the free disassembly of the split rolls to achieve cross-directional speed variation. Any small section of roll can be replaced according to different needs, offering strong flexibility and compatibility. It operates smoothly and is easy to use. 2. This equipment controls the roller speed by changing the gear transmission ratio. The gears are always meshed, reducing wear, extending service life, and saving costs. The entire structure is very compact, small, and lightweight.

[0008] Compared with the prior art, the method of the present invention has the following advantages: I. The split-roll structure breaks free from the constraints of the traditional concept of a single-piece roll design, representing a completely new approach. It involves designing the overall roll as multiple independently controllable split rolls along the axial direction. Depending on actual needs, the structural dimensions of each split roll can be identical or different, and they can be modularly replaced. Furthermore, the rotational speed of the split rolls during rolling can be adjusted in real time. II. In traditional asynchronous rolling, the frictional forces on the upper and lower surfaces of the sheet are opposite, resulting in surface friction along the thickness direction. This invention achieves opposite frictional forces on the upper and lower surfaces, as well as adjacent left and right surfaces, during the rolling process. The sheet is simultaneously subjected to the interactive action of rubbing in both the width and thickness directions, i.e., rubbing and twisting deformation. Therefore, the rolled sheet undergoes greater shear deformation. Compared to the former, the range of action is significantly expanded and the degree is more intense, which is more conducive to refining the microstructure and improving uniformity. Third, traditional rolling processes for forming low-plasticity metal sheets often require additional pretreatment steps or multiple loading passes, resulting in a lengthy process, low production efficiency, and a significant increase in costs. When the rolls are modified to a split structure and rolled at individually adjustable speeds, the sheet is subjected to complex bidirectional shear stress, which facilitates the activation of more slip systems. This is highly beneficial for short-process forming of low-plasticity metal sheets. Fourth, the segmented variable-speed controlled rolling method can reduce or eliminate surface defects such as scratches, wrinkles, and oxidation, making the surface of the sheet smoother and significantly improving surface quality. Simultaneously, the deformation zone generates higher frictional heat, leading to an increase in material temperature, which helps improve the sheet's plasticity and ductility. Fifth, due to the intense shear deformation caused by simultaneous twisting and rolling along the width and tumbling along the thickness, the grains in the rolled zone of the sheet are fully refined, and the microstructure distribution is more uniform. Compared with traditional rolling, this invention can minimize strain hardening of the material, and the unique loading method can reduce local stress concentration, improve the mechanical properties of the sheet, and increase the service life of the sheet. VI. Since the operating status of each split roll can be controlled independently, the deformation behavior and coordination sequence of different parts of the sheet can be quantitatively controlled by adjusting the speed and rolling force range of the split rolls, so as to realize different rolling actions and meet the processing requirements of various complex shapes. This provides greater flexibility for manufacturing high-precision, complex-shaped, high-performance sheet parts and effectively improves production efficiency. VII. The stress state of the segmented roll controlled rolling method is relatively complex, resulting in significant differences in flow velocity in different parts of the deformation zone. During the rolling process, the plate not only experiences complex shear forces in the width and thickness directions, but also bears the compressive stress of each segmented roll, thus affecting the mechanical properties of the rolled plate. Attached Figure Description

[0009] Figure 1. Schematic diagram of the rolling mill components; Figure 2. Schematic diagram of split rolls; Figure 3. Rolling process flow chart; Figure 4. Schematic diagram of the roll structure. Specific implementation methods

[0010] The experimental scheme of this device will be described in detail below with reference to the accompanying drawings. The drawings are only for illustrative purposes and do not fully express the ideas of this invention.

[0011] Specific Implementation Method 1: This implementation method is illustrated in Figures (1), (2), (3), and (4). It includes a segmented variable speed controlled rolling forming device 5, a metal sheet 4, a high-temperature heating furnace 6, and a rolling pusher 7. This implementation method is completed in the following steps: 1. Replace the rolls on the traditional rolling mill with the segmented variable speed controlled rolling forming device of this invention, transforming it into a high-performance plate rolling device 5 capable of wide-direction variable speed rolling; 2. Cut and grind the metal sheet 4 to dimensions l1×d1×h1, place the appropriately sized sheet in a propanol solution for cleaning to remove surface impurities and oil, then clean with an ethanol solution and air-dry for later use; 3. Preheat the high-temperature heating furnace 6 to the required rolling temperature, then place the metal sheet in and hold it at that temperature for t1 time to ensure sufficient preheating; 4. Adjust rolling parameters such as reduction and rolling speed, start the rolling mill, remove the preheated sheet, and use the pusher 7 to feed the sheet between the upper and lower rolls for rolling; 5. Correct the rolled metal sheet, retaining only the well-formed sheet.

[0012] Specific Implementation Method Two: This implementation method is illustrated in Figures (1), (2), (3), and (4). This implementation method includes a segmented variable speed controlled rolling forming device 5, a metal sheet 4, a high-temperature heating furnace 6, and a rolling pusher 7. This implementation method is completed by the following steps: 1. Replace the upper and lower rolls of the traditional rolling mill with the segmented variable speed controlled rolling forming device of this invention, with the upper and lower rolls having the same number of segments, so as to transform it into a high-performance plate rolling device 5 capable of wide-direction variable speed rolling; 2. Cut and grind the metal sheet 4 with dimensions of l1×d1×h1, put the plate of appropriate size into a propanol solution for cleaning to remove surface impurities and oil stains, and then clean it with an ethanol solution and air dry it for later use; 3. Preheat the high-temperature heating furnace 6 to the temperature required for rolling, and put the metal sheet in, and keep it at the temperature for t1 time to fully preheat it; 4. Adjust the rolling parameters such as reduction amount and rolling speed, start the rolling mill, take out the preheated plate, and use the pusher 7 to send the plate between the upper and lower rolls for rolling; 5. Correct the rolled metal sheet and retain the regular plate.

[0013] Specific Implementation Method 3: This implementation method is illustrated in conjunction with Figures (1), (2), (3), and (4). This implementation method includes a segmented variable speed controlled rolling forming device 5, a metal sheet 4, a high-temperature heating furnace 6, and a rolling pusher 7. This implementation method is completed by the following steps: 1. Replace the upper and lower rolls of the traditional rolling mill with the segmented variable speed controlled rolling forming device of this invention, with different numbers of segments on the upper and lower rolls, to transform it into a high-performance plate rolling device 5 capable of wide-direction variable speed rolling; 2. Cut and grind the metal sheet 4 with dimensions of l1×d1×h1, place the sheet of suitable size into a propanol solution for cleaning to remove surface impurities and oil stains, then clean it with an ethanol solution and air dry it for later use; 3. Preheat the high-temperature heating furnace 6 to the temperature required for rolling, then place the metal sheet in it and hold it at the temperature for t1 time to ensure sufficient preheating; 4. Adjust the rolling parameters such as reduction amount and rolling speed, start the rolling mill, take out the preheated sheet, and use the pusher 7 to send the sheet between the upper and lower rolls for rolling; 5. Correct the rolled metal sheet and retain the regular sheet.

Claims

1. A method for segmented, variable-speed controlled rolling forming of high-performance metal sheets, characterized in that, The apparatus for implementing this method includes: Several split rolls (1), an integral roll (2), and a mill stand (3) are distributed along the roll axis. The split rolls (1) adopt a planetary gear system structure, which consists of planetary gears (8), a fixed shaft (9), a sleeve (10), a main shaft (11), and a sun gear (12). The speed is input to the sun gear (12) through the main shaft (11). The sun gear (12) and the gear ring in the sleeve (10) are meshed and driven by the planetary gears (8) on the fixed shaft (9). The transmission ratio of the split rolls (1) is changed by changing the size of the sun gear (12), the size of the planetary gears (8), and the number of teeth of the sleeve (10), thereby realizing the change of the rotation speed of the split rolls (1). This method is achieved through the following steps: Step 1: Adjust the speed of the roll by changing the transmission ratio of the planetary gear (8) and the sun gear (12) inside the split roll (1) to achieve the effect of wide-segmented different speeds; Step 2: Immerse the metal plate with dimensions l1×d1×h1 in acetone solution, clean the surface impurities, rinse it with anhydrous ethanol, and dry it for later use; Step 3: Place the clean metal slab into the heating furnace for preheating, set it to the corresponding heating temperature, and hold it for t1 time; Step 4: Adjust the input speed ω of the main shaft (11), and the rolling speed of the split roll (1) is ω1, ω2...ω n Step 5: After the preheated slab is pushed into the space between the rolls by the pusher, the shape of the rolled metal sheet is corrected and the scrap area is cut off according to actual needs. If annealing is required, it is put into the heating furnace for processing.

2. The high-performance metal sheet segmented differential speed controlled rolling forming method according to claim 1, characterized in that, By adjusting the number of teeth of the planetary gear (8) and the sun gear (12), the transmission ratio between them can be changed, thereby achieving segmented different speeds; when the speeds of the split rolls are different, the surface deformation of the plate is different, and high-performance metal plates with different structures can be prepared.

3. The method for segmented, variable-speed controlled rolling of high-performance metal sheets according to claim 1, characterized in that, When using split rolls (1) to replace the original rolls of the mill, the planetary gears (8) inside the split rolls (1) are fixed together with crankshafts instead of the segmented fixing method.

4. The high-performance metal sheet segmented differential speed controlled rolling forming method according to claim 1, characterized in that, According to actual needs, the structural dimensions of each split roll (1) are the same or different and are modularly replaced. The rotation speed of the split roll (1) can also be adjusted in real time during rolling.

5. The high-performance metal sheet segmented differential speed controlled rolling forming method according to claim 1, characterized in that, The number of segments n of the split rolls (1) can be reasonably adjusted according to the size and performance requirements of the sheet material. n is set to 2≤n≤10, and the roll length can be allocated according to the actual processing requirements.

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