Casting Reduction Apparatus with Segmented Backup Rolls
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Solution Overview
Problem
Existing casting product reduction technologies fail to simultaneously decrease center segregation and porosity while preventing internal cracks, as they either lack sufficient reduction force or lead to bulging deformation due to insufficient support and stiffness.
Innovation Solution
A casting product reduction apparatus with a pair of press rolls and backup rolls arranged in a specific configuration, allowing for distributed load reception and uniform reduction application, which includes a large-diameter portion for mid-width reduction and divided backup rolls for enhanced support and reduced deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the roll diameter is decreased to support the long side surfaces, then the support coverage is improved, but the roll becomes insufficient in stiffness and deforms to deflect
Solution Approach 1:
The backup roll is divided into multiple segments along the axial direction, with each segment independently supported by bearing parts. This segmentation allows the backup roll to maintain adequate stiffness through distributed support while still providing comprehensive support coverage to the long side surfaces of the casting product.
2Reliability
If backup rolls are arranged to prevent casting product support rolls from deforming, then the support stability is improved, but the casting product cannot be subjected to sufficient reduction force
Solution Approach 1:
The backup roll acts as an intermediary element between the frame and the casting product support rolls. It provides stable support to prevent roll deformation while allowing the casting product support rolls to apply sufficient reduction force to the casting product, as the backup roll absorbs and distributes the support functions.
3Force
If divided rolls are used with bearing parts between them, then the load distribution is improved, but bulging deformation occurs at the bearing parts
Solution Approach 1:
The bearing parts are extracted from the casting product support rolls and relocated to exclusively support the backup roll. This separation prevents the bearing parts from being subjected to both the reduction force and the load distribution functions simultaneously, eliminating the bulging deformation that occurs when they are combined in the casting product support rolls.
4Manufacturing precision
If rolling reduction is applied to decrease porosity, then the product quality is improved, but internal cracks may occur due to excessive reduction
Solution Approach 1:
The backup roll provides partial support coverage, focusing on supporting the casting product support rolls at critical locations rather than providing continuous support along the entire length. This partial support is sufficient to prevent roll deformation and enable controlled reduction that decreases porosity without causing excessive stress that would lead to internal cracks.
Data Source
AI summary
The present invention is a casting product reduction apparatus that applies reduction to a casting product drawn from a mold with a sufficient reduction force and thereby can surely decrease center segregation and porosity and suppress occurrence of internal cracks so as to manufacture a high-quality casting product and includes: a pair of casting product press rolls that hold and press the casting product therebetween; backup rolls that support the casting product press rolls; and a pair of frames arranged to face each other, wherein three or more sets of the casting product press roll and the backup roll are arranged in a casting product drawing direction on each of the frames, and wherein a reduction means that decreases and increases a distance between the frames is provided at two or more places on the pair of frames.