Additively Manufactured Roll Stand for Lower Mass and Higher Stroke Rates
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Solution Overview
Problem
Existing roll stands in cold Pilger rolling mills are heavy, limiting their speed and throughput, and require significant material for construction, which increases costs and weight.
Innovation Solution
The roll stand is optimized using additive manufacturing, combining direct and indirect methods to reduce material usage and weight while maintaining strength, allowing for a lighter and more flexible design with integrated transverse struts and replaceable components, and optimized using the finite element method for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional manufacturing methods are used for roll stands, then structural strength is sufficient, but weight becomes excessive and limits speed and throughput
Solution Approach 1:
The roll stand is divided into multiple components (frame, support structures, roll holders) that can be manufactured separately using additive manufacturing and then assembled. This segmentation allows optimization of each component's material usage while maintaining overall structural integrity and strength.
Solution Approach 2:
Additive manufacturing enables the creation of complex three-dimensional structures with optimized material distribution throughout the roll stand. Instead of traditional uniform thickness designs, the structure incorporates variable density and topology optimized for specific load paths, dramatically reducing weight while preserving strength.
2Ease of manufacture
If additive manufacturing is used to reduce material usage, then weight decreases and flexibility increases, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into modular stages: digital modeling, additive manufacturing of individual components, and final assembly. This segmentation makes the complex additive manufacturing process more manageable and allows for easier quality control and troubleshooting at each stage.
Solution Approach 2:
The invention optimizes manufacturing parameters such as layer thickness, infill density, and printing orientation to balance manufacturing complexity with final product performance. By carefully controlling these parameters, the process becomes more predictable and easier to execute while still achieving the desired weight reduction and design flexibility.
3Productivity
If roll stand mass is reduced to increase stroke rates, then productivity increases, but structural integrity must be maintained
Solution Approach 1:
The roll stand incorporates curved and rounded structural elements rather than sharp angles and flat surfaces. These curved geometries better distribute stress and mechanical loads throughout the structure, maintaining structural integrity while using less material. The organic shapes are particularly well-suited to additive manufacturing processes.
Solution Approach 2:
The invention employs composite material structures combining different materials or material densities within the same roll stand components. High-strength materials are used in critical load-bearing areas, while lighter materials are used in non-critical areas, optimizing the strength-to-weight ratio to enable higher stroke rates.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a roll stand that is stronger and lighter, increasing stroke rates by over 10% and reducing mass by more than 10% compared to conventional stands, enhancing mill productivity at lower costs.
Implementation Method 1
the roll stand is at least partially, preferably completely, formed as a cast part and a casting mold of the roll stand is directly produced by additive manufacturing
Implementation Method 2
The connection to the roll shaft can particularly preferably be produced by shrinking the roll body onto the roll shaft
Data Source
AI summary
A roll stand, wherein at least two rolls for forming a workpiece are accommodated in the stand, and wherein a rolling force acting during the forming is supported by the roll stand, wherein the roll stand is produced by means of additive manufacturing.