Composite Plate Rolling With Recessed Roller Burr Control
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Solution Overview
Problem
The metal composite rolling process often results in flashings and burrs due to inaccurate width dimensions and excessive friction, leading to additional production costs and potential damage to the rolling device.
Innovation Solution
A method involving placing a first plate and a second plate in a recess around a roller, with the harder plate having striations to prevent burrs and flashings, and using controlled rollers to combine them into a composite plate, including heating and solid solution treatments for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If side rollers are pressed tightly against side surfaces of working rollers, then width dimension control is improved, but device reliability deteriorates due to excessive friction causing damage to the rolling device
Solution Approach 1:
A side support roller is introduced as an intermediary component between the side rollers and working rollers. This mediator roller receives the pressing force from the side rollers and transmits it to the working rollers through its circumference, distributing the force more evenly and reducing direct friction contact between side rollers and working rollers, thereby preventing device damage while maintaining width dimension control
Solution Approach 2:
The invention changes the contact parameter by having the side support roller contact the working roller at its circumferential surface rather than direct side-to-side contact. This parameter change in contact geometry reduces friction intensity while maintaining the necessary constraining force for width control
2Reliability
If side rollers are merely in loose contact with working rollers, then device reliability is maintained, but manufacturing precision deteriorates due to flashings and burrs occurring in the width direction
Solution Approach 1:
The side support roller acts as a force transmission intermediary that enables effective width control without requiring tight direct contact between side rollers and working rollers. The mediator roller transmits the constraining force through its circumferential contact, providing sufficient control to prevent flashings and burrs while maintaining loose contact that protects device reliability
Solution Approach 2:
The force transmission path is segmented into multiple stages: side rollers apply force to the side support roller, which then transmits force to the working roller through circumferential contact. This segmentation of the force transmission chain allows for distributed force application that prevents both excessive friction damage and insufficient width control
3Device complexity
If traditional rolling process is used without recess, then device complexity is reduced, but manufacturing precision deteriorates due to flashings and burrs
Solution Approach 1:
The recess structure is pre-formed on the working roller surface before the rolling process begins. This preliminary structural preparation creates a built-in constraint that prevents material from protruding during rolling, eliminating flashings and burrs without requiring additional complex device components
Solution Approach 2:
The width control function is merged into the working roller itself through the recess structure. Instead of requiring separate side support mechanisms, the recess is directly formed on the working roller, combining the rolling and width control functions into a single component, thereby maintaining device simplicity while improving precision
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 effectively prevents burrs and flashings, enhances the structural strength and quality of the composite plate, and reduces production costs by streamlining the process.
Implementation Method 1
at least one of the first surface and the second surface is roughened so that at least one of the first surface and the second surface is provided with a plurality of striations
Implementation Method 2
controlling a first roller and a second roller to rotate, thereby rolling to combine the first plate and the second plate into a composite plate
Implementation Method 3
including heating and solid solution treatments for enhanced bonding
Implementation Method 4
including heating and solid solution treatments for enhanced bonding
Data Source
AI summary
A method for making a metal material composite includes: contacting a first surface of a first plate with a second surface of a second plate; placing the first plate and the second plate in a recess in a circumferential direction of a first roller such that a third surface of the second plate contacts a bottom wall of the recess in a circumferential, the third surface being opposite the second surface, the first plate having a greater hardness than the second plate; and controlling a first roller and a second roller to rotate, thereby rolling to combine the first plate and the second plate into a composite plate, where a fourth surface of the first plate contacts a surface of the second roller and the fourth surface is opposite the first surface during the rolling.