Combined Ring Rolling for Spherical Valve Body
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Solution Overview
Problem
Conventional methods for forming spherical valve bodies are energy-intensive, inefficient, and result in poor forming accuracy and high production costs due to the need for repeated heating and forging, and the nonsynchronous profile shaping and diameter expansion during ring rolling.
Innovation Solution
A combined ring rolling method involving two stages: surface cross rolling and general ring rolling, where the ring blank is designed with a rectangular section and specific dimensions to achieve continuous partial plastic deformation, allowing for simultaneous profile shaping and diameter expansion with controlled metal flow, reducing energy consumption and increasing material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forging method is used with repeated heating and forging, then the valve body can be formed, but energy consumption increases and production efficiency decreases
Solution Approach 1:
The ring rolling process is divided into two distinct stages: profile shaping stage (with passive rolls) and diameter expanding stage (without passive rolls). This segmentation allows each stage to focus on a specific forming objective, achieving complete spherical profile while avoiding the need for repeated heating and forging operations, thus reducing energy consumption while maintaining forming accuracy.
Solution Approach 2:
The invention implements continuous ring rolling in one uninterrupted process from initial ring blank to final forged ring. The continuous plastic deformation eliminates the need for repeated heating cycles and intermediate forging operations, maintaining continuous useful action throughout the forming process, thereby significantly reducing energy consumption while achieving the required forming accuracy.
2Length of moving object
If conventional ring rolling is used for spherical valve body, then the ring diameter can be expanded, but profile shaping and diameter expanding are nonsynchronous leading to incomplete profile shaping
Solution Approach 1:
The ring rolling process is divided into two distinct stages: profile shaping stage (with passive rolls) and diameter expanding stage (without passive rolls). This segmentation allows each stage to focus on a specific forming objective, achieving complete spherical profile while avoiding the need for repeated heating and forging operations, thus reducing energy consumption while maintaining forming accuracy.
Solution Approach 2:
The invention dynamically adjusts the rolling gap configuration between different stages. Passive rolls are introduced during the profile shaping stage to control metal flow and shape the spherical profile, then removed during the diameter expanding stage to allow unrestricted radial expansion. This dynamic adjustment ensures synchronous achievement of both profile shaping and diameter expansion.
3Manufacturing precision
If ring blank performing under press machine is added to avoid profile shaping defects, then the profile can be shaped better, but workstage increases and operating complexity increases
Solution Approach 1:
The invention merges the profile shaping function into the ring rolling process itself by introducing passive rolls that work in conjunction with the main roll. This integration eliminates the need for separate press machine performing operations, combining multiple functions (profile shaping and diameter expansion) into a single unified ring rolling operation, thereby reducing workstage complexity while maintaining profile shaping quality.
Solution Approach 2:
Passive rolls are introduced as intermediary elements during the profile shaping stage. These passive rolls mediate the metal flow between the main roll and the ring blank, controlling and directing the plastic deformation to achieve precise spherical profile shaping without requiring separate press machine operations, thus simplifying the overall process while improving profile quality.
4Manufacturing precision
If conventional forging method is used with multiple workstages, then the valve body can be formed, but production time increases and working efficiency decreases
Solution Approach 1:
The invention implements continuous ring rolling in one uninterrupted process from initial ring blank to final forged ring. The continuous plastic deformation eliminates the need for repeated heating cycles and intermediate forging operations, maintaining continuous useful action throughout the forming process, thereby significantly reducing energy consumption while achieving the required forming accuracy.
Solution Approach 2:
The ring rolling process is divided into two distinct stages: profile shaping stage (with passive rolls) and diameter expanding stage (without passive rolls). This segmentation allows each stage to focus on a specific forming objective, achieving complete spherical profile while avoiding the need for repeated heating and forging operations, thus reducing energy consumption while maintaining forming accuracy.
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 method significantly reduces energy consumption, increases material utilization, and improves forming accuracy, resulting in lower production costs and higher efficiency compared to conventional forging and general ring rolling techniques.
Implementation Method 1
the ring blank is designed with a rectangular section and specific dimensions to achieve continuous partial plastic deformation, allowing for simultaneous profile shaping and diameter expansion
Data Source
AI summary
This invention relates to a combined ring rolling method for spherical valve body, which has the following procedures: 1) design for ring blank by computing ring blank volume and selecting reasonable rolling ratio according to the dimensions of forged ring; 2) design for rolling gap which includes the shapes and dimensions of working surfaces of main roll, mandrel and passive rolls according to the dimensions of ring blank and forged ring, the stable deformation condition of combined ring rolling and structure requirement of rolling equipment; 3) rolling forming with three stages of surface cross rolling, ring rolling and shaping by controlling of feeding speed of main roll and working positions of passive rolls. This invention has the technical economical advantages of low consumptions of energy and materials, high productivity and low production cost.