Fe-based Amorphous Alloy Ribbon Polishing for Unwinding Collapse
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Solution Overview
Problem
The existing methods for manufacturing Fe-based amorphous alloy ribbons often result in unwinding collapse and a low space factor, making it difficult to produce high-quality wound bodies with a high space factor from the early stage of production.
Innovation Solution
The use of a polishing brush roll with specific brush bristle conditions, including a free length of 30-50 mm and a density of 0.30-0.60 bristles/mm², is implemented to polish the chill roll, which helps in forming a uniform alloy ribbon and preventing unwinding collapse by reducing thickness deviations and maintaining a high space factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to manufacture Fe-based amorphous alloy ribbon, then production can proceed, but unwinding collapse occurs and space factor becomes low
Solution Approach 1:
The invention changes the surface condition parameters of the chill roll by specifying precise polishing conditions (brush bristle free length of 30-50 mm, density of 0.30-0.60 bristles/mm², and push-in amount of 1-10 mm). These parameter changes create optimal surface roughness that prevents unwinding collapse and maintains high space factor from the early stage of production
Solution Approach 2:
The invention applies preliminary polishing action to the chill roll surface before alloy ribbon production. By pre-establishing the optimal surface condition through controlled polishing, the system prevents unwinding collapse and ensures high space factor from the beginning of production rather than correcting issues after they occur
2Manufacturing precision
If polishing conditions are not optimized, then manufacturing process is simpler, but thickness deviation increases causing unwinding collapse
Solution Approach 1:
The invention specifies precise parameter ranges for the polishing brush roll (bristle free length: 30-50 mm, density: 0.30-0.60 bristles/mm², push-in amount: 1-10 mm) to achieve optimal surface roughness on the chill roll. These controlled parameter changes produce consistent thickness uniformity in the alloy ribbon while managing device complexity through defined specifications
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 effectively suppresses unwinding collapse and achieves a high space factor from the early stage of production, ensuring the quality of the wound body and the magnetic properties of the iron core.
Implementation Method 1
polishing the peripheral surface of the chill roll with a polishing brush roll
Implementation Method 2
discharging a molten alloy onto a chill roll to form an Fe-based amorphous alloy ribbon
Implementation Method 3
cooling the coated film on the peripheral surface to form an Fe-based amorphous alloy ribbon
Data Source
Figure 1
AI summary
A method of manufacturing an Fe-based amorphous alloy ribbon includes forming a coated film of a molten alloy on a peripheral surface of a chill roll that has been subjected to polishing using a polishing brush roll, cooling the coated film on the peripheral surface, and then winding the Fe-based amorphous alloy ribbon, which has been peeled off by a peeling means, on a wind-up roll, to obtain a wound body of an Fe-based amorphous alloy ribbon. The polishing brush roll includes a roll axis member and a polishing brush that is equipped with a plurality of brush bristles and satisfies the following condition (1) and condition (2) while rotating axially in a reverse direction to the chill roll. • Condition (1): Free length of brush bristles is more than 30 mm but no more than 50 mm. • Condition (2): Density of brush bristles at the brush bristle tip is more than 0.30 bristles/mm2 but no more than 0.60 bristles/mm2.