Deep-Rolling Machine for Railway Axles with Multi-Zone Roller Pairs
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Solution Overview
Problem
Existing machine tools for deep rolling wheelset axles of railway vehicles can only process one area at a time due to the need for manual roll changes, limiting the efficiency and versatility in machining different sections of the axle.
Innovation Solution
A machine tool design featuring three pairs of deep-rolling rollers, where each pair is dedicated to specific areas (steering knuckle, press fit, and shaft shank) with the ability to pivot and move in the y-direction, allowing simultaneous machining of multiple axle zones, and adjustable infeed for uniform deep rolling force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual roll changes are used to process different areas of the axle, then the machine can be simpler in structure, but the processing time increases and productivity decreases
Solution Approach 1:
The machine tool is divided into multiple independent roller pairs, each dedicated to processing specific axle zones. The first roller pair processes the steering knuckle and transition zone, the second roller pair processes the press fit area, and the third roller pair processes the shaft shank. This segmentation allows simultaneous processing of multiple areas without manual intervention.
Solution Approach 2:
Each roller pair is designed with multi-functionality, capable of processing different axle zones through pivoting movements and y-direction displacement. The rollers can be positioned and oriented to access various areas of the axle, allowing a single machine to perform multiple processing functions simultaneously.
2Device complexity
If only one area is processed at a time, then the machine structure can be simpler, but the variety of processing possibilities is limited
Solution Approach 1:
The roller pairs are equipped with dynamic positioning capabilities through pivoting mechanisms and y-direction displacement. This allows the rollers to adapt their position and orientation to process different axle zones, including transitions between zones with varying diameters, enhancing the machine's versatility.
Solution Approach 2:
Each roller pair is specifically configured with appropriate dimensions and positioning capabilities for processing particular axle zones. The local optimization of each roller's characteristics enables effective processing of specific areas while maintaining overall machine simplicity.
3Productivity
If multiple roller pairs are added for simultaneous processing, then productivity increases, but the device complexity increases
Solution Approach 1:
Multiple roller pairs are merged into a single integrated machine tool structure with common support elements, drive mechanisms, and control systems. This combining approach enables simultaneous processing of multiple axle zones while avoiding the complexity of multiple separate machines.
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
Enables simultaneous processing of multiple areas of a wheelset shaft, increasing the variety of processing possibilities and reducing the time required for machining, thereby enhancing the service life and reliability of wheelset axles by introducing compressive residual stresses.
Implementation Method 1
deep rolling tools, with which different areas of a wheelset shaft can be processed... the introduction of compressive residual stresses in the surface of crankshafts can prevent cracks from forming or cracks that have already occurred can be brought to a standstill
Data Source
AI summary
The invention relates to a machine, in particular a machine tool, for deep-rolling axles (5) for wheelsets of railway vehicles, having two lathe centres (16) for receiving an axle (5) at each of their two ends, having a device for driving the axle (20, 22), having two pairs of deep-rolling tools, which can be moved in the directions x, y and z of the machine tool in order to work on the stubs of the axle (5), and having bracing and advancing devices for the deep-rolling tool. The problem solved is that of creating such a machine tool by means of which the axles (5) of wheelsets for railway vehicles can be deep-rolled prior to the wheel discs being pressed on. The problem is solved by the deep-rolling tools consisting of more than two pairs of deep-rolling rollers (14, 15, 23, 25, 24, 26), of which each pair is provided for deep-rolling a certain length portion (axial zone 1 and 2, 3 or 4) of the axle (5).