Compound Roll Inner Core Outer Sleeve Fusion
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Solution Overview
Problem
The high cost and mass of compound rolls used in hot rolling processes due to the use of virgin cemented carbide materials, which results in significant waste and increased maintenance costs as the rolls wear down and need frequent re-grinding.
Innovation Solution
A method of forming a compound roll by fusing a sintered inner core made of lower-cost, recycled cemented carbide with a sintered outer sleeve of virgin cemented carbide, reducing the overall mass and cost of the roll while maintaining performance through a bonding interface that is heated to a predetermined temperature for fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If virgin cemented carbide is used for the entire roll, then the roll has high strength and durability, but the cost and mass increase significantly
Solution Approach 1:
The roll is divided into two regions with different material properties: the outer sleeve uses virgin cemented carbide for high strength and wear resistance where it contacts the steel, while the inner core uses recycled cemented carbide for cost reduction and mass reduction. This local differentiation resolves the contradiction by applying high-performance material only where necessary.
Solution Approach 2:
The roll combines two types of cemented carbide materials (virgin and recycled) into a composite structure. The outer sleeve and inner core are bonded together through diffusion bonding to create a unified composite roll that achieves both strength requirements and mass/cost reduction.
2Weight of stationary object
If recycled cemented carbide is used for the inner core, then cost and mass are reduced, but bonding strength at the interface may be compromised
Solution Approach 1:
The bonding process uses controlled parameter changes: heating the assembled outer sleeve and inner core to a predetermined temperature to enable diffusion bonding at the interface. This thermal parameter change ensures strong bonding between the virgin and recycled cemented carbide materials without compromising interface strength.
Solution Approach 2:
The mechanical assembly of the outer sleeve and inner core is replaced by diffusion bonding through heating. This substitution of mechanical joining with thermal-diffusion bonding creates a stronger, more reliable interface that can withstand rolling forces while allowing the use of lower-density recycled material in the core.
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 reduces maintenance costs and load on mill bearings by using a lower-density carbide for the inner core, allowing for a more cost-effective and efficient rolling process without compromising the roll's physical properties.
Implementation Method 1
When the assembled sintered inner core and sintered at least one outer sleeve are heated to a predetermined temperature, the inner core and outer sleeve are fused together at the bonding interface to form the compound roll
Implementation Method 2
the inner core and outer sleeve are fused together at the bonding interface
Data Source
Figure 1
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AI summary
A compound roll (20) includes a sintered inner core (22) of a first cemented carbide and at least one sintered outer sleeve (24) of a second cemented carbide disposed around the inner core. The outer sleeve and inner core each have a joining surface (26,28), wherein when the inner core and outer sleeve are assembled each joining surface is brought into contact to form a bonding interface (30) there between. When the assembled sintered inner core (22) and sintered outer sleeve (24) are heated to a predetermined temperature the sintered inner core and sintered outer sleeve are fused together at the bonding interface (30) to form the unitary compound roll (20). In order to reduce the overall cost of the compound roll (20), a lower cost cemented carbide, or a cemented carbide with a lower density can be used for the inner core and fused to a sintered outer sleeve of a virgin cemented carbide, thereby reducing the powder cost and/or reducing the overall mass of the compound roll itself.