Cross-Wedge Rolling Mill Structure for Fast Large-Axle Mold Change
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Solution Overview
Problem
Existing cross wedge rolling mills are inadequate for efficiently producing large-scale axles with diameters of 200-250 mm and lengths of 2000-2800 mm, as they lack the structural capabilities and mold replacement efficiency required for high-speed rail and construction machinery applications.
Innovation Solution
A large-scale axle intelligent cross wedge rolling mill is designed, comprising a main transmission device, a memorial arch unit, worm-gear pressing devices, a roll assembly, and guide devices, which enables quick mold replacement, dynamic monitoring of rolling forces, and improved product accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fast forging machines are used to prepare large-scale axles, then the production process can be completed, but the production cycle is long, product accuracy is low, and energy consumption is high
Solution Approach 1:
The patent replaces traditional fast forging machines with a cross-wedge rolling system that uses controlled plastic deformation through wedge-shaped rollers. This substitution enables continuous forming without the need for repeated hammering cycles, thereby reducing production time while improving dimensional accuracy and surface quality of the axle components
Solution Approach 2:
The invention changes the fundamental forming parameters by using cross-wedge rolling instead of impact forging. The process parameters include controlled rolling speed, wedge angle, and rolling force, which allow for precise control of material flow and deformation, resulting in higher product accuracy and reduced production cycle
2Productivity
If precision forging machines are used to prepare large-scale axles, then the forging speed is doubled and cutting amount is reduced, but the production cycle still takes at least 4 minutes and quality stability is poor
Solution Approach 1:
The patent replaces precision forging machines with a cross-wedge rolling system that provides continuous, controlled plastic deformation. This substitution eliminates the intermittent nature of forging cycles, enabling continuous forming that improves both productivity and quality stability through consistent process parameters and reduced variability
Solution Approach 2:
The cross-wedge rolling process enables continuous deformation of the workpiece as it passes through the rolling zone, eliminating the start-stop nature of forging operations. This continuity ensures consistent material flow and deformation, improving quality stability while increasing productivity through uninterrupted processing
3Productivity
If existing cross wedge rolling devices are used for large-scale shafts, then the equipment structure is simple, but the equipment cannot meet the needs of efficient preparation of large-scale axles with diameter 200-250 mm and length 2000-2800 mm
Solution Approach 1:
The patent segments the cross-wedge rolling system into modular components including separate drive mechanisms, adjustable wedge rollers, and independent support structures. This segmentation allows the equipment to be scaled and configured for large-scale axle production while maintaining structural simplicity and ease of maintenance
Solution Approach 2:
The invention introduces dynamic capabilities to the rolling equipment through adjustable rolling speeds, variable wedge angles, and controllable rolling forces. These dynamic features enable the simple equipment structure to adapt to different production requirements for large-scale axles, improving preparation efficiency without significantly increasing structural complexity
4Quantity of substance
If rolling mill molds are made large in size and weight for large-scale axles, then the production capacity is increased, but the mold replacement time increases from 0.5 days to 2 days
Solution Approach 1:
The patent segments the large rolling mill molds into separable sections or modules that can be independently handled and replaced. This segmentation allows the molds to maintain the necessary large size and weight for producing large-scale axles while enabling faster replacement by working on smaller, manageable components rather than replacing entire massive molds at once
Solution Approach 2:
The invention introduces intermediary devices such as hydraulic lifting systems, mechanical hoists, or automated handling mechanisms that facilitate the replacement of large, heavy molds. These intermediary tools mediate between the large mold size and the need for quick replacement, reducing manual handling time and enabling faster mold changes despite the increased mold dimensions
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
The intelligent cross wedge rolling mill significantly reduces mold replacement time from 2 days to 0.5 days, enhances product accuracy and size consistency, and allows for real-time monitoring and adjustment of rolling processes, thereby improving overall production efficiency and quality.
Implementation Method 1
worm-gear pressing devices
Implementation Method 2
cross wedge rolling is an efficient and clean plastic forming technology for parts
Implementation Method 3
two output shafts of the transfer case are connected with an upper transmission shaft and a lower transmission shaft through two universal couplings, respectively
Implementation Method 4
main transmission device comprises a main drive motor, a primary reducer and a transfer case
Implementation Method 5
two guide devices, wherein... the two guide devices are located at a front side and a rear side of the memorial arch unit
Data Source
AI summary
A large-scale axle intelligent cross wedge rolling mill for rail transit includes a main transmission device, a memorial arch unit, two worm-gear pressing devices, a roll assembly and two guide devices. The separation sleeves are engaged with the upper slide shaft and the lower slide shaft, respectively. Two lower shaft necks are detachably connected with the left end surface and the right end surface of the lower roller, respectively; two upper shaft necks are detachably connected with the left end surface and the right end surface of the upper roller, respectively, so that the quick disconnection of the upper and lower rollers with the upper and lower shaft necks is able to be achieved, so as to quickly operate and install the roll to meet the requirement of quick mold replacement, thus improving the flexibility of rolling.