Deep Rolling Roller Mounting with Conical Bolt Head
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Solution Overview
Problem
Existing deep-rolling tools face challenges in absorbing forces in the feed direction during deep-rolling, requiring a mounting system that can apply large radial forces while allowing for easy, play-free, and cost-effective fastening, as well as quick roller replacement or design changes.
Innovation Solution
A deep-rolling roller mounting system featuring a truncated cone-shaped receptacle for the bolt head and a circular cylinder-shaped receptacle for the cover, secured with socket head screws, allowing for precise and secure fastening and easy roller exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a fixed roller mounting system is designed to apply large radial forces for deep-rolling, then the roller can effectively perform deep-rolling operations, but the mounting system becomes more complex and difficult to assemble/disassemble
Solution Approach 1:
The mounting system is segmented into modular components: a housing with recesses, a bolt head with conical fastening surface, a cover with cylindrical fastening surface, and socket head screws. This segmentation allows each component to be optimized independently while maintaining overall functionality, resolving the contradiction between force transmission capability and assembly complexity
Solution Approach 2:
Instead of using a traditional threaded bolt connection that requires complex threading and alignment, the invention inverts the approach by using conical and cylindrical fastening surfaces that mate together. The bolt head features a conical surface that fits into a conical recess in the housing, while the cover has a cylindrical surface that receives the bolt, creating a simplified yet robust connection that maintains radial force transmission
2Reliability
If a secure and precise fastening system is used to absorb feed direction forces, then the roller remains stable during operation, but the fastening becomes more complex and expensive
Solution Approach 1:
The invention changes the geometric parameters of the fastening surfaces - specifically using a conical surface with a specific angle for the bolt head recess and a matching conical surface on the bolt head, combined with a cylindrical surface on the cover. These parameter choices optimize both the radial force transmission and the absorption of feed direction forces while keeping the structure simple and cost-effective
Solution Approach 2:
The fastening system combines different geometric forms (conical and cylindrical surfaces) in a composite manner, where the conical surfaces handle radial loading and the cylindrical cover provides lateral support. This composite approach allows the system to absorb forces in multiple directions simultaneously while maintaining structural simplicity
3Productivity
If the deep-rolling roller is designed for quick replacement, then damaged or different design rollers can be changed rapidly, but the fastening mechanism becomes less secure and precise
Solution Approach 1:
The housing is pre-formed with recesses that precisely guide the bolt head into position, and the cover is pre-configured with the cylindrical fastening surface. This preliminary preparation ensures that when the roller is replaced, the components automatically align and engage with high precision, maintaining manufacturing accuracy while enabling quick replacement
Solution Approach 2:
The conical and cylindrical fastening surfaces act as intermediaries between the bolt head, cover, and housing. These intermediary surfaces provide a simple yet precise interface that guides assembly automatically, ensuring accurate positioning and secure fastening without requiring complex alignment procedures, thus enabling both quick replacement and high precision
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A deep rolling roller (1) is arranged detachably on a housing (2). The deep rolling roller (1) is mounted freely rotatably on a bolt between a bolt head (7) and a cover (20), wherein the housing (2) comprises a recess (6) for the deep rolling roller (1), a seat (10) for the bolt head (7) and a seat (19) for the cover (20). The seat (10) for the bolt head (7) is designed as a partial surface (11, 14) of a truncated cone and has a concentric collar (23) in the direction of the rotational axis (24) of the deep rolling roller (1), while the seat (19) for the cover (20) is designed as a partial surface (16, 17) of a circular cylinder.