Adjustable Roll Shaping for Metallic Wave Profiles
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Solution Overview
Problem
Existing methods and devices are unable to efficiently shape metallic flat materials into wavy profiles with varying heights and cross-sections, and manufacture composite materials with such profiles, limiting flexibility and increasing production costs.
Innovation Solution
A continuous method using meshing tooth systems of rotating rolls to shape metallic flat materials into wave profiles, with adjustable center distance and flank clearance between rolls to achieve desired profile heights and cross-sections, allowing for gentle shaping of hard alloys and adaptation to material characteristics, and subsequent bonding with additional flat materials for composite production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If meshing rolls with fixed geometry are used for shaping, then the shaping process is simple and reliable, but the flexibility to produce varied profile heights and cross-sections is limited
Solution Approach 1:
The patent applies the dynamics principle by making the rolls adjustable during the shaping process. The center distance between rolls can be modified before or during shaping to control profile height, and the rotary position of rolls can be adjusted to control profile cross-section. This dynamic adjustability allows production of varied wave profiles without replacing rolls, resolving the contradiction between versatility and device complexity.
2Strength
If traditional shaping methods are used for hard alloys, then high shaping forces are required, but this causes excessive material stress and potential damage
Solution Approach 1:
The patent applies parameter changes by modifying the center distance between rolls and the rotary position of rolls during the shaping process. This allows control over the degree of meshing and contact pressure, enabling gentle shaping of hard alloys with low elongation at break. By adjusting these parameters, the shaping forces are reduced while still achieving the desired wave profile, preserving material strength.
3Productivity
If rolls are replaced to change profile specifications, then shaping precision is maintained, but production time increases due to tooling changes
Solution Approach 1:
The patent eliminates tool replacement by implementing dynamically adjustable rolls. The center distance and rotary position can be modified during production to change profile heights and cross-sections. This allows rapid reconfiguration without stopping production for tooling changes, significantly reducing non-production time and increasing productivity.
4Ease of manufacture
If high profile heights are shaped, then material utilization is improved, but the shaping forces and complexity increase
Solution Approach 1:
The patent achieves high profile heights by modifying the center distance between rolls during the shaping process. This parameter change allows the rolls to create deeper waves without requiring more complex machinery. The adjustable center distance enables control over the degree of material deformation, achieving high profile heights while maintaining ease of manufacture.
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
Enables the rapid and cost-effective shaping of varied wave profiles with high mechanical characteristics similar to solid materials but with significantly lower weight, suitable for applications like panels and air conditioning elements, without the need for frequent tool replacement or long non-production times.
Implementation Method 1
the shaping of the metallic flat material... is carried out with the aid of meshing tooth systems of the two rotating rolls
Implementation Method 2
modifying in planned manner the centre distance between the rolls before or optionally even during the shaping process in such a way that the desired profile height is shaped in the wave profile
Implementation Method 3
by relative rotation of the rolls with respect to one another to adjust the flank clearance between the meshing tooth systems
Implementation Method 4
at least one further flat material is applied and fixed to the thus shaped wavy flat material
Data Source
AI summary
The invention relates to a method and a device for shaping a metallic flat material to give a metallic wave profile, in which the flat material is passed between two meshing tooth systems of two rotating, toothed rolls. For setting a desired profile height, the centre distance between the rolls can be adjusted, and for presetting of a profile cross-section the flank clearance between the meshing tooth systems can be adjusted. The invention furthermore relates to a method and a plant for the continuous manufacture of a composite material from a metallic wave profile shaped with the aid of the above-described method or the above-described device, and at least one further flat material, which is firmly joined to the wave profile to give the composite material.