Asymmetric Skew Rolling Mill for Accurate Diameter Reduction
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Solution Overview
Problem
Existing skew rolling technologies face challenges in achieving high outer diameter dimensional accuracy during diameter reduction of pipe or bar materials, particularly when reducing the diameter from large to small, due to roll shaft deflection and interference issues with multiple rolling rolls of equal diameters.
Innovation Solution
A skew rolling mill with three or more rolling rolls, where at least one roll has a diameter of 90% or less than another, allowing for asymmetric arrangement and reduced roll diameter variation to minimize interference and maintain high accuracy, with a drive roll and non-drive roll configuration to manage torque and bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If three or more rolling rolls of equal diameter are arranged along the circumferential direction to perform diameter reducing rolling, then outer diameter dimensional accuracy is improved, but roll shaft deflection occurs under rolling load which reduces accuracy
Solution Approach 1:
The patent applies asymmetry by configuring rolling rolls with different diameters instead of equal diameters. Specifically, at least one rolling roll has a diameter that is 90% or less of another rolling roll's diameter, creating an asymmetric arrangement that reduces roll shaft deflection while maintaining manufacturing precision through the differential diameter configuration
Solution Approach 2:
The patent applies local quality by making each rolling roll have different local properties (different diameters) suited to their specific positions and load conditions. This allows each roll to be optimized for its local stress environment, with smaller diameter rolls positioned to handle specific loading conditions that would cause deflection in equal-diameter configurations
2Productivity
If three or more rolling rolls are arranged to reduce outer diameter of material, then diameter reduction capability is improved, but interference between rolling rolls occurs which restricts reduction range
Solution Approach 1:
The asymmetric diameter configuration allows rolling rolls to be arranged in a manner that reduces interference between adjacent rolls. By having different diameters, the rolls can be positioned to accommodate a wider range of reduction ratios without the geometric interference that occurs in equal-diameter arrangements, thereby improving adaptability while maintaining productivity
3Productivity
If all rolling rolls are made small to roll small diameter material, then small diameter rolling capability is improved, but roll shaft deflection increases which reduces outer diameter dimensional accuracy
Solution Approach 1:
The patent applies local quality by assigning different diameters to different rolling rolls based on their specific functional requirements. Larger diameter rolls are used where structural stability and deflection resistance are critical, while smaller diameter rolls are used where compact rolling capability is needed, optimizing both small diameter rolling capability and dimensional accuracy through localized property differentiation
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 configuration enables diameter reduction with excellent outer diameter dimensional accuracy over a wide range, reducing material damage and improving uneven thickness issues, while maintaining high rigidity and torque transmission.
Implementation Method 1
the material to be rolled made of a pipe or bar material is fed between the rolls being rotated, and pulled in and caused to pass through between the rolls while being rotated by the rotation of the rolls
Data Source
Figure 1A~3
Figure 4A~5
Figure 6A~7B
AI summary
Materials to be rolled ranging from large to small in diameter undergo diameter reducing rolling with excellent outer diameter dimensional accuracy. A rolling mill includes three or more rolling rolls (2) aligned along a circumferential direction and arranged such that each rotary shaft thereof is skewed with respect to a pass line P of a material to be rolled (1), in which the material to be rolled (1) made of a pipe or bar material is caused to pass through between the three or more rolling rolls (2) while being rotated to undergo diameter reducing rolling. At least one rolling roll (2) selected from the three or more rolling rolls (2) is smaller in roll diameter than at least one other rolling roll (2). When, among the three or more rolling rolls (2), at least one rolling roll (2) having a relatively maximum roll diameter is defined as a maximum diameter rolling roll (2A) and at least one rolling roll (2) smaller in roll diameter than the maximum diameter rolling roll (2A) is defined as a small diameter rolling roll (2B), the small diameter rolling roll (2B) has a roll diameter equal to or less than 90% of the roll diameter of the maximum diameter rolling roll (2A) .