Cutting Roller Metallic Groove Sleeve Assembly
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Solution Overview
Problem
The existing cutting rollers for rotary cutting machines, made of fiber composite materials with metallic layers applied via thermal spraying, are complex, time-consuming, and costly to produce, with grooves requiring post-application incorporation, which complicates the manufacturing process and increases production costs.
Innovation Solution
The solution involves arranging and fixing a metallic grooved sleeve coaxially on the fiber composite support body, allowing for independent optimization of manufacturing processes, with the grooved sleeve being produced from tubular metallic material in a cost-effective manner, and incorporating grooves either before or after assembly, using methods like shrinking, gluing, or latching connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin metallic layer is applied to the fiber-reinforced composite support body using a thermal spraying process, then the cutting roller achieves the required functional properties, but the manufacturing process becomes complex, time-consuming, and expensive
Solution Approach 1:
The cutting roller is divided into two separate components: a fiber-reinforced composite support body and a metallic groove sleeve. These components are manufactured independently using optimized processes for each material, then assembled together. This segmentation eliminates the need for thermal spraying and allows each component to be manufactured using the most suitable process for its material properties.
Solution Approach 2:
The invention combines two different manufacturing approaches: composite material forming for the support body and metal forming/machining for the groove sleeve. By merging these separate manufacturing processes and assembling the components, the invention achieves the functional benefits of both materials while avoiding the complexity of thermal spraying.
2Reliability
If a thin metallic layer is applied using thermal spraying, then the cutting roller achieves required properties, but production time and costs increase due to the complex and energy-intensive process
Solution Approach 1:
By segmenting the cutting roller into separately manufacturable components (support body and groove sleeve), each can be produced using efficient, dedicated processes without the time-consuming thermal spraying step. The groove sleeve can be manufactured using standard metal forming and machining operations, significantly reducing production time and energy consumption.
Solution Approach 2:
The groove sleeve is pre-manufactured with grooves formed through efficient machining or forming processes before assembly. This preliminary action eliminates the need for post-spraying groove creation and allows parallel manufacturing of both components, improving overall production efficiency.
3Manufacturing precision
If the grooves are machined after the metallic layer is applied, then the cutting roller functions properly, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The grooves are formed in the metallic groove sleeve during its initial manufacturing process, before assembly with the support body. This preliminary groove formation simplifies the overall manufacturing process by eliminating post-assembly machining steps and allows the grooves to be created when the metal is in its most workable state.
Solution Approach 2:
By separating the groove formation operation into the groove sleeve manufacturing process rather than a post-assembly operation, the invention reduces manufacturing complexity. The groove sleeve can be dedicated to groove formation using optimized metal forming or machining processes.
4Strength
If steel is applied to the fiber-reinforced composite support structure using thermal spraying, then the cutting roller achieves required durability, but the process becomes especially expensive and energy-intensive
Solution Approach 1:
The cutting roller is segmented into a composite support body and a separate metallic groove sleeve that provides the required durability. This segmentation eliminates the energy-intensive thermal spraying process while maintaining the functional benefits of having a metallic component with appropriate material properties for durability and groove formation.
Solution Approach 2:
The invention changes the manufacturing approach from applying metal through thermal spraying (high energy consumption) to manufacturing a separate metal component using conventional forming and machining processes (lower energy consumption). This parameter change in the manufacturing process significantly reduces energy requirements while achieving the same functional outcome.
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 simplifies and reduces the cost of producing cutting rollers by allowing separate optimization of the support body and grooved sleeve manufacturing, enabling precise groove formation and ensuring even groove distribution, while accommodating thermal expansion differences between materials, thus enhancing the cutting roller's stability and operational efficiency.
Implementation Method 1
the at least one grooved sleeve is shrunk onto the support body
Implementation Method 2
accommodating thermal expansion differences between materials
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a cutting roller (1) for a roller cutting machine, in particular for the processing of wide film webs, having a plurality of ring-shaped circumferential grooves (6) extending perpendicular to an axis of rotation (4), wherein the cutting roller (1) comprises a hollow-cylindrical supporting body (2) of a fiber composite material, characterized in that at least one metallic groove sleeve (5, 50, 51) forming the grooves (6) is arranged coaxially on and fixed to the supporting body (2).