Metal bar tube material roller-type groove bending and brittle breaking blanking system and method

Abstract

The present application relates to the technical field of metal plastic forming process and equipment, and provides a metal rod pipe material roller type rolling groove bending and brittle fracture blanking system and method, the system comprises a feeding device, a first rolling groove die, a second rolling groove die, a first light roller, a second light roller, a bending roller and a bending matching roller; the first and second rolling groove dies are respectively arranged on the first and second light rollers to cooperatively realize rod pipe material rolling groove bending; the bending roller and the bending matching roller are oppositely arranged to realize bending and brittle fracture after rod pipe material rolling groove bending; the first light roller and the bending roller, and the second light roller and the bending matching roller are coaxially arranged side by side; and the feeding device sends the rod pipe material to a preset position. The method comprises feeding positioning, rolling groove bending, bending, and feeding again, and is cyclically repeated. The present application combines the rolling groove bending and bending two processes into one process through a roller type rolling process, greatly improves the production efficiency, can be used for rod pipe materials with different diameters, has a wide application range, can realize large-batch precise blanking, and has a wide application prospect.

Description

Technical Field

[0001] This invention relates to the field of metal plastic forming technology and equipment, and in particular to a rolling groove bending and brittle fracture blanking system and method for metal bars and tubes. Background Technology

[0002] Metal bars and tubes are in high demand and have a wide range of applications, making them an important component in the machinery manufacturing industry. Currently, most bar and tube parts required in industrial production, such as bearing rollers, bearing inner and outer rings, some bushings, and retaining rings, are obtained from blanking raw materials. There are three main blanking processes: sawing, turning, and shearing. While sawing can achieve high dimensional accuracy, it results in significant material loss at the saw cut and lower production efficiency compared to shearing. Turning produces high dimensional accuracy and a smooth end face, but it also leads to significant material waste and low production efficiency. Shearing is highly efficient and has no metal material loss, but it easily creates horseshoe shapes at the ends, resulting in defects such as uneven end faces, collapse, and elliptical shapes. The end faces are also often accompanied by burrs and cracks. Therefore, a reasonable blanking process must be adopted to obtain qualified blanks. In addition to requiring a flat cross-section, small burrs, material savings, high productivity, and low pollution, the cutting of metal bars and tubes must also ensure minimal distortion of the cross-sectional shape, ideally achieving precision cutting, to avoid secondary processing due to substandard cross-sectional quality.

[0003] Many scholars at home and abroad have been researching ways to improve the quality of the cross-section of metal rods and tubes during blanking, and are also seeking other new blanking processes and devices.

[0004] This material feeding process and equipment design features a compact workflow, high production efficiency, high dimensional accuracy, smooth cross-section, and no material loss. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a rolling groove bending and brittle fracture blanking system and method for metal bars and tubes. This invention combines the two processes of rolling groove bending and rolling into one process for the first time. The process is compact, the design is ingenious, it is easy to automate, and it significantly saves time and production costs. It can also be used for metal bars and tubes of different diameters, with a wide range of applications, high production efficiency, and the ability to perform precision blanking in large batches.

[0006] The present invention adopts the following technical solution:

[0007] On one hand, the present invention provides a rolling mill groove bending and brittle fracture feeding system for metal bars and tubes, including a feeding device, a first groove mold, a second groove mold, a first smooth roller, a second smooth roller, a bending roller and a bending matching roller;

[0008] The first and second smooth rollers are arranged opposite each other, the first grooving die is set on the first smooth roller, and the second grooving die is set on the second smooth roller; the first grooving die and the second grooving die cooperate to achieve grooving at the set feeding position of the metal rod / tube material;

[0009] The bending roller and the bending matching roller are arranged opposite to each other and are used to bend and break metal bars and tubes after they are rolled into grooves, thus completing the unloading process.

[0010] The first optical roller and the bending roller are arranged side by side and coaxially, and the second optical roller and the bending roller are arranged side by side and coaxially.

[0011] A set gap is left between the first and second rolling mill dies, and between the bending roll and the bending mating roll; the metal bar or tube is grooved, bent, and brittlely broken within the set gap;

[0012] The feeding device is used to deliver metal rods and tubes to a preset position.

[0013] In any of the possible implementations described above, a further implementation method is provided, wherein the bending roller sequentially includes a base circle section, a first transition section, a tapered section, and a second transition section;

[0014] The base circular segment has a circular cross-section;

[0015] The first transition section is used to connect the base circle section and the starting end of the tapered section; the first transition section is provided with a broken tapered boss that gradually rises in the direction perpendicular to the circumferential direction of the roller surface;

[0016] The tapered section is provided with a broken tapered boss of fixed height;

[0017] The second transition section is used to connect the tail end of the tapered section and the base circle section;

[0018] The bending roller has an axial taper, the size of which matches the taper section of the bending roller.

[0019] In addition to any of the possible implementations described above, another implementation is provided in which the first groove die and the second groove die are respectively embedded on the first smooth roller and the second smooth roller. The groove die is a consumable part and is assembled, which can greatly save production costs and the service life of the feeding device.

[0020] In addition to any of the possible implementations described above, another implementation is provided in which the radial spacing between the first and second grooving dies, and between the bending roll and the bending mating roll, is adjustable, so as to cut metal long bars and tubes of different diameters (10-100mm).

[0021] In addition to any of the possible implementations described above, a further implementation is provided in which the feeding device includes a first circular drive wheel and a second circular drive wheel arranged opposite to each other, the distance between the first circular drive wheel and the second circular drive wheel being adjustable for clamping or releasing the metal rod / tube material; the feeding direction of the metal rod / tube material is the circumferential tangent direction when the first circular drive wheel and the second circular drive wheel rotate.

[0022] In addition to any of the possible implementations described above, another implementation is provided in which the taper of the broken taper boss of the taper segment is 5°-9°.

[0023] In addition to any of the possible implementations described above, another implementation is provided in which both the first roll die and the second roll die are provided with convex ribs of gradually increasing height for rolling V-grooves on the metal rod or tube material. The length of the convex ribs is greater than the circumference of the metal rod or tube material. The position of the convex ribs corresponds to the base circle segment of the bending roll.

[0024] In addition to any of the possible implementations described above, another implementation is provided where the included angle α of the V-groove is 90°, the radius r of the groove bottom fillet is 0.1–0.3 mm, and the ratio of the groove depth h to the diameter D of the metal rod / tube material is 0.15–0.2. The taper is selected primarily based on the material's mechanical properties and microstructure; it should be neither too small nor too large. Too small a taper will prevent the die from rolling through the material in one revolution; too large a taper will result in poor material cross-sectional quality. The specific taper can be determined based on experimental results.

[0025] In addition to any of the possible implementations described above, another implementation is provided in which the first optical roller and the second optical roller are arranged vertically or horizontally, and the corresponding bending roller and bending mating roller are arranged vertically or horizontally.

[0026] In addition to any of the possible implementations described above, another implementation is provided in which the first roll die and the bending roll are provided as a whole or separately, and the second roll die and the bending mating roll are provided as a whole or separately.

[0027] In addition to any of the possible implementations described above, another implementation is provided in which the metal rod or tube is made of a cold-brittle material, including high-strength steel and alloy steel.

[0028] On the other hand, the present invention also provides a method for blanking metal bars and tubes by roller milling in a groove due to brittle fracture. The method uses the aforementioned metal bar and tube roller milling in a groove due to brittle fracture, and the method includes:

[0029] S1. Feeding and positioning: The first and second circular drive wheels of the feeding device clamp the metal rod and tube material. The first and second circular drive wheels rotate, and the metal rod and tube material is pushed to the set feeding position under the action of friction. The first and second circular drive wheels are released, and the metal rod and tube material is released from the clamping state.

[0030] S2, Grooving: The first and second smooth rollers rotate at the same speed and in the same direction, and the metal bars and tubes rotate synchronously. Under the action of the convex edges of the first and second grooving dies, V-grooves are gradually opened; the bending roller and the bending matching roller rotate synchronously. During the grooving process of the metal bars and tubes, the bending roller runs in the base circle section.

[0031] S3, Bending: The bending roller rotates and enters the first transition section, the tapered section, and the second transition section in sequence. The metal rod and tube material is broken by the combined bending action of the breaking tapered boss and breaking tapered concave platform in the tapered section, completing one feeding. During operation, a small-amplitude variable concentrated force is applied to the metal rod and tube material that has already been cut with V-grooves, so that under the action of stress concentration effect and fatigue crack propagation, the metal rod and tube material is precisely fed.

[0032] S4. The feeding device clamps the remaining part of the metal rod and tube again, and repeats steps S1-S3 to achieve continuous automatic feeding of the metal rod and tube.

[0033] In addition to any of the possible implementations described above, a further implementation is provided in which the first and second smooth rollers are provided with feeding troughs, and the corresponding positions of the bending rollers are also provided with feeding troughs. The advantage of providing feeding troughs is that it eliminates the need to readjust the distance between the first and second smooth rollers, and also eliminates the need to readjust the distance between the bending roller and the bending mating roller. When the bar stock is in the feeding trough position, the bar stock can be fed inward through the feeding trough; after being fed to the set position, the smooth rollers and bending rollers rotate, and the feeding troughs move away from the bar stock due to rotation. At this time, the non-feeding trough portions of the first and second smooth rollers clamp the bar stock. The feeding troughs eliminate the need to adjust the roller spacing during feeding, rolling, and bending processes, which is beneficial for continuous feeding and improves efficiency.

[0034] In addition to any of the possible implementations described above, another implementation is provided in which the groove depth of the feeding trough is 0.5-1mm.

[0035] The beneficial effects of this invention are as follows: For the first time, the two processes of grooving and bending are combined into one process through roll rolling, which greatly improves production efficiency. It can also be used for metal rods and tubes of different diameters, has a wide range of applications, can be used for large-scale precision cutting, conforms to the concepts of green manufacturing and precision manufacturing, and has broad application prospects. Attached Figure Description

[0036] Figure 1The figure shown is a schematic diagram of the appearance of a metal bar / tube material roller-type groove bending and brittle fracture feeding system according to an embodiment of the present invention.

[0037] Figure 2 The diagram shown is a structural schematic of a metal bar / tube material roller-type groove bending and brittle fracture feeding system according to an embodiment of the present invention.

[0038] Figure 3 The diagram shown illustrates the relationship between the smooth roller, bending roller, and bending mating roller in this embodiment.

[0039] Figure 4 The diagram shown is a schematic representation of the unfolded surface of the bending roller in the embodiment.

[0040] Figure 5 The diagram shown illustrates the relationship between the bending roller and the mating roller in the embodiment.

[0041] Figure 6 A schematic diagram of the four stages of a method for blanking metal rods and tubes by bending and brittle fracture in a roller mill according to an embodiment of the present invention.

[0042] Figure 7 The diagram shown is a schematic diagram of the grooved bar material in the embodiment.

[0043] Figure 8 The diagram shown is a schematic of the bending roller in the embodiment.

[0044] Figure 9 The diagram shows a comparison of the fracture effects of the conventional method and the method of the present invention; (a) top side view; (b) top view.

[0045] In the figure: 1-Metal rod / tube material; 2-Second smooth roller; 3-Bending roller; 4-Bending roller; 5-First smooth roller; 6-First circular drive wheel; 7-Second circular drive wheel; 9-Feeding section (rod / tube material); 10-First rolling die; 11-Second rolling die (not shown); 41-Base circle section; 42-First transition section; 43-Tapered section; 44-Second transition section. Detailed Implementation

[0046] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be noted that the technical features or combinations of technical features described in the following embodiments should not be considered in isolation, but can be combined with each other to achieve better technical effects.

[0047] like Figure 1 , Figure 2 As shown, an embodiment of the present invention provides a metal rod and tube material roller-type groove bending and brittle fracture feeding system, including a feeding device, a first groove mold 10, a second groove mold 11, a first smooth roller 5, a second smooth roller 2, a bending roller 4, and a bending matching roller 3;

[0048] The first light roller 5 and the second light roller 2 are arranged opposite to each other. The first groove die 10 is arranged on the first light roller 5, and the second groove die 11 is arranged on the second light roller 2. The first groove die 10 and the second groove die 11 cooperate to groove at the set feeding position of the metal rod tube 1.

[0049] The bending roller 4 and the bending matching roller 3 are arranged opposite to each other and are used to bend and break the metal rod and tube material 1 after it is rolled into the groove, so as to complete the unloading.

[0050] The first smooth roller 5 and the bending roller 4 are arranged coaxially side by side, and the second smooth roller 2 and the bending roller 3 are arranged coaxially side by side; Figure 3 As shown;

[0051] A set gap is left between the first rolling die 10 and the second rolling die 11, and between the bending roller 4 and the bending mating roller 3; the metal rod tube 1 is grooved, bent and brittlely broken in the set gap;

[0052] The feeding device is used to deliver the metal rod / tube material 1 to a preset position.

[0053] In one specific embodiment, the first smooth roller 5 and the second smooth roller 2, and the bending roller 4 and the bending mating roller 3 are symmetrical about the metal rod and tube 1, and the line connecting the starting points of the first groove die 10 and the second groove die 11 passes through the center line of the metal rod and tube 1.

[0054] In one specific embodiment, such as Figure 4 , Figure 5 As shown, the bending roller 4 sequentially includes a base circle section 41, a first transition section 42, a tapered section 43, and a second transition section 44;

[0055] The base circular segment 41 has a circular cross-section;

[0056] The first transition section 42 is used to connect the starting end of the base circle section 41 and the tapered section 43; the first transition section 42 is provided with a broken tapered boss that gradually rises in the direction perpendicular to the circumferential direction of the roller surface;

[0057] The tapered section 43 is provided with a broken tapered boss of fixed height;

[0058] The second transition section 44 is used to connect the tail end of the tapered section 43 with the base circle section 41.

[0059] In one specific embodiment, such as Figure 8As shown, the bending roller 3 has an axial taper. The cross-sectional diameter on the side of the contact surface with the second smooth roller 2 is larger (equal to the diameter of the second smooth roller 2), while the cross-sectional diameter on the other side is smaller, forming the axial taper. The size of the axial taper matches the taper segment 43 of the bending roller 4. For example, in this embodiment, the axial taper is equal to the taper of the broken taper boss of the taper segment 43 of the bending roller 4. It should be noted that the bending roller 3 can have various forms; this embodiment is only one. As long as the bending roller 3 and the bending roller 4 do not interfere with each other and can constrain the feeding section after the bar / tube material 1 is bent, it is acceptable.

[0060] The unfolded diagram of bending roller 4 is as follows Figure 4 As shown.

[0061] In one specific embodiment, the feeding device includes a first circular drive wheel 6 and a second circular drive wheel 7 arranged opposite to each other. The distance between the first circular drive wheel 6 and the second circular drive wheel 7 is adjustable, used to clamp or release the metal rod / tube material 1. The feeding direction of the metal rod / tube material 1 is the circumferential tangent direction when the first circular drive wheel 6 and the second circular drive wheel 7 rotate. Figure 1 As shown.

[0062] In one specific embodiment, the taper of the broken taper boss of the taper segment 43 is 5°-9°.

[0063] In one specific embodiment, both the first roll die 10 and the second roll die 11 are provided with convex ribs of gradually increasing height, which are used to roll V-shaped grooves on the metal rod tube 1. The length of the convex ribs is greater than the circumference of the metal rod tube 1. The position of the convex ribs corresponds to the base circle segment 41 of the bending roll.

[0064] When no plastic deformation occurs at the tip of the V-groove, i.e., within the elastic range, its stress concentration factor is only related to the geometry of the metal rod / tube material 1, and its expression is K. t =f(r,h,α,D). When the local stress at the root of the V-groove reaches the yield limit of the material, plastic deformation will occur at the tip, which will alleviate the high elastic stress and reduce the stress concentration factor.

[0065] The optimal geometric parameters are: an included angle α of 90° in the groove shape, a bottom fillet radius r of 0.1–0.3 mm, and a groove depth h to bar diameter D ratio of 0.15–0.2. (See attached image) Figure 7 Under these design parameters, production efficiency is high, cutting dimensional accuracy is high, and the cross-section is flat.

[0066] In one specific embodiment, the first light roller 5 and the second light roller 2 are arranged vertically or horizontally, and the corresponding bending roller 4 and bending mating roller 3 are arranged vertically or horizontally.

[0067] In one specific embodiment, the metal rod / tube 1 is made of a cold-brittle material, including high-strength steel and alloy steel.

[0068] like Figure 6 As shown in the figure, an embodiment of the present invention provides a method for blanking metal rods and tubes by roller milling in a groove due to brittle fracture. The method uses the aforementioned metal rod and tube blanking system by roller milling in a groove due to brittle fracture, and the method includes:

[0069] S1. Feeding and positioning: The first circular drive wheel 6 and the second circular drive wheel 7 of the feeding device clamp the metal rod and tube material 1. The first circular drive wheel 6 and the second circular drive wheel 7 rotate, and the metal rod and tube material 1 is pushed axially to the set feeding position under the action of friction. The first circular drive wheel 6 and the second circular drive wheel 7 are released, and the metal rod and tube material 1 is released from the clamping state.

[0070] The metal rod / tube material 1 can be placed on the guide plate for convenient positioning and support; the feeding device is located on the feeding side.

[0071] S2, Grooving: The first smooth roller 5 and the second smooth roller 2 rotate at the same speed and in the same direction, and the metal rod and tube material 1 rotates synchronously. Under the action of the convex edges of the first grooving mold 10 and the second grooving mold 11 (which are respectively set on the first smooth roller 5 and the second smooth roller 2), a V-shaped groove is gradually opened; the bending roller 4 and the bending mating roller 3 rotate synchronously. During the grooving process of the metal rod and tube material 1, the bending roller 4 and the bending mating roller 3 run in the base circle section 41;

[0072] S3, Bending: Bending roller 4 and bending mating roller 3 rotate sequentially into the first transition section 42, the tapered section 43, and the second transition section 44. The unloading section 9 of the metal rod / tube material 1 is broken by the combined bending action of the breaking tapered boss and breaking tapered concave platform of the tapered section 43, completing one unloading operation.

[0073] A small, variable concentrated force is applied to the metal rod / tube material 1 that has already been cut with a V-groove, so that under the action of stress concentration effect and fatigue crack propagation, the metal rod / tube material 1 can be precisely cut.

[0074] S4. The feeding device clamps the remaining part of the metal rod and tube 1 again, and repeats steps S1-S3 to realize the continuous automatic feeding of the metal rod and tube 1.

[0075] In one specific embodiment, the first light roller 5 and the second light roller 2 are provided with feeding grooves, and the corresponding positions of the bending roller 4 and the bending mating roller 3 are also provided with feeding grooves. Preferably, the groove depth of the feeding groove is 0.5-1mm.

[0076] like Figure 9As shown, the cross-section obtained by the traditional shearing method is shown on the right side of Figures (a) and (b), while the cross-section obtained by the device and method of the present invention is shown on the left side of Figures (a) and (b). A comparison clearly shows that the cross-section obtained by the method of the present invention is smoother, has fewer burrs, and higher precision.

[0077] The material cutting method of this invention has the advantages of compact design process, high production efficiency, high cutting size accuracy, flat cross-section, and no material loss.

[0078] While several embodiments of the present invention have been provided herein, those skilled in the art should understand that modifications can be made to these embodiments without departing from the spirit of the invention. The above embodiments are merely exemplary and should not be construed as limiting the scope of the invention.

Claims

1. A metal bar tube blank roll groove bending and brittle fracture blanking system, characterized by, The system includes a feeding device, a first groove die, a second groove die, a first smooth roller, a second smooth roller, a bending roller, and a bending mating roller; The first and second smooth rollers are arranged opposite each other, the first grooving die is set on the first smooth roller, and the second grooving die is set on the second smooth roller; the first grooving die and the second grooving die cooperate to achieve grooving at the set feeding position of the metal rod / tube material; The bending roller and the bending matching roller are arranged opposite to each other and are used to bend and break metal bars and tubes after they are rolled into grooves, thus completing the unloading process. The first optical roller and the bending roller are arranged side by side and coaxially, and the second optical roller and the bending roller are arranged side by side and coaxially. A set gap is left between the first and second grooving dies, and between the bending roller and the bending mating roller; The metal rod or tube material is grooved, bent, and brittlely broken within the set gap; The feeding device is used to feed the metal rod and tube material to a preset position; The bending roller comprises, in sequence, a base circle section, a first transition section, a tapered section, and a second transition section; The base circular segment has a circular cross-section; The first transition section is used to connect the base circle section and the starting end of the tapered section; the first transition section is provided with a broken tapered boss that gradually rises in the direction perpendicular to the circumferential direction of the roller surface; The tapered section is provided with a broken tapered boss of fixed height; The second transition section is used to connect the tail end of the tapered section and the base circle section; The mating roller has an axial taper, the size of which matches the taper section of the bending roller.

2. The metal rod tube stock roll bending and breakage blanking system as claimed in claim 1, wherein, The feeding device includes a first circular drive wheel and a second circular drive wheel arranged opposite to each other. The distance between the first circular drive wheel and the second circular drive wheel is adjustable and used to clamp or release the metal rod or tube material. The feeding direction of the metal rod or tube material is the circumferential tangent direction when the first circular drive wheel and the second circular drive wheel rotate.

3. The metal bar / tube roll forming groove bending and brittle fracture feeding system as described in claim 1, characterized in that, The taper of the broken taper boss in the taper segment is 5°-9°.

4. The metal bar / tube roll forming groove bending and brittle fracture feeding system as described in claim 1, characterized in that, Both the first and second rolling dies are provided with raised ribs of gradually increasing height, used to roll V-shaped grooves on metal bars and tubes. The length of the raised ribs is greater than the circumference of the metal bars and tubes. The position of the raised ribs corresponds to the base circle of the bending roll.

5. The metal bar / tube roll forming groove bending and brittle fracture feeding system as described in claim 4, characterized in that, The included angle α of the V-shaped groove is 90°, the radius r of the bottom fillet is 0.1~0.3mm, and the ratio of the groove depth h to the diameter D of the metal rod / tube is 0.15~0.

2.

6. The metal bar / tube roll forming groove bending and brittle fracture feeding system as described in claim 1, characterized in that, The first and second optical rollers are arranged vertically or horizontally, and the corresponding bending rollers and bending mating rollers are arranged vertically or horizontally.

7. The metal bar / tube roll forming groove bending and brittle fracture feeding system as described in claim 1, characterized in that, The metal rods and tubes are made of cold-brittle materials, including high-strength steel and alloy steel.

8. A method for blanking metal bars and tubes by roller milling in a grooved bending process to prevent brittle fracture, characterized in that... The method uses the metal bar / tube roll forming groove bending and brittle fracture blanking system as described in any one of claims 1-7, the method comprising: S1. Feeding and positioning: The first and second circular drive wheels of the feeding device clamp the metal rod and tube material. The first and second circular drive wheels rotate, and the metal rod and tube material is pushed to the set feeding position under the action of friction. The first and second circular drive wheels are released, and the metal rod and tube material is released from the clamping state. S2, Grooving: The first and second smooth rollers rotate at the same speed and in the same direction, and the metal bars and tubes rotate synchronously. Under the action of the convex edges of the first and second grooving dies, V-grooves are gradually opened; the bending roller and the bending matching roller rotate synchronously. During the grooving process of the metal bars and tubes, the bending roller runs in the base circle section. S3, Bending: The bending roller rotates and enters the first transition section, the tapered section and the second transition section in sequence. The blanking section of the metal bar and tube is broken by the bending action of the tapered boss in the tapered section, completing one blanking. S4. The feeding device clamps the remaining part of the metal rod and tube again, and repeats steps S1-S3 to achieve continuous automatic feeding of the metal rod and tube.

9. The method for blanking metal bars and tubes by roller milling in a grooved bending process as described in claim 8, characterized in that, The first and second light rollers are provided with feeding grooves, and the corresponding positions of the bending rollers are also provided with feeding grooves.

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