Deep Rolling Tool with Flexible Fork and Spring-Loaded Rollers
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Solution Overview
Problem
Conventional deep rolling tools are bulky, slow, and non-adjustable, requiring high pressure and multiple passes due to their hydraulic nature, making them inefficient and costly for processing components with complex geometries.
Innovation Solution
A deep rolling tool with a flexible fork structure and crowned rollers, which applies compressive stress without the need for hydraulic systems, allowing for adjustable force distribution and improved contact zones, enabling efficient processing of components with varying geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional hydraulic tools with ball bearing clamping elements are used, then clamping force can be applied, but the tools become bulky and difficult to process components
Solution Approach 1:
The patent removes the hydraulic system entirely from the tool design, extracting only the essential function of applying force through spring-loaded fingers. This eliminates the bulky hydraulic pump and control valves while maintaining the core clamping function through a much more compact mechanical-spring mechanism.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with a spring-based mechanical system. The spring-loaded fingers provide the necessary clamping force through elastic deformation rather than hydraulic pressure, significantly reducing the tool's volume while maintaining force application capability.
2Force
If hydraulic ball bearing clamping elements are used, then clamping force is provided, but the contact zone is small requiring many passes and thus the tool is slow
Solution Approach 1:
The patent transitions from point-contact ball bearings to line-contact or面-contact fingers. The finger elements provide a larger contact area with the component surface, allowing more material to be processed in each pass and reducing the total number of passes required, thereby increasing productivity.
3Force
If conventional hydraulic tools are used, then clamping force can be applied, but high pressure pump is required adding to complexity and cost
Solution Approach 1:
The patent extracts and removes the high-pressure hydraulic pump and associated control systems from the tool. The clamping force is now generated locally by spring elements within the tool itself, eliminating the need for external high-pressure fluid systems and significantly reducing overall system complexity.
Solution Approach 2:
The spring-loaded fingers are self-actuating, using the elastic potential energy stored in the springs to automatically apply and release clamping force. This self-service mechanism eliminates the need for external hydraulic power sources and control systems, simplifying the overall system.
4Ease of manufacture
If conventional tools are used, then processing can be performed, but they are non-adjustable and may not be usable with certain component geometries/thicknesses
Solution Approach 1:
The patent employs flexible or adjustable finger elements that can adapt their position and contact points to match different component geometries and thicknesses. This dynamic adaptability allows the same tool to be used across a variety of component types without requiring multiple specialized tools, improving versatility while maintaining ease of manufacture.
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 solution significantly enhances fatigue life and surface finish of components, reducing processing time and costs by providing a more compact, adjustable, and efficient method for applying compressive stress, potentially achieving greater than 10× improvement in fatigue life.
Implementation Method 1
a first spring-loaded finger (211) and a second spring-loaded finger (212) of the plurality of rolling elements (201)
Implementation Method 2
configured to apply a compressive stress to articles received by the deep rolling tool
Data Source
AI summary
A device and methods are provided for deep rolling. In one embodiment, a deep rolling tool for applying compressive stress with rolling elements includes a flexible fork having a base section and a plurality of fork arms and a plurality of rolling elements, wherein each rolling element is mounted to a fork arm with eccentric roller bushings, wherein each rolling element is mounted at the distal end of a fork arm, and wherein the rolling elements are configured to apply a compressive stress to articles received by the deep rolling tool.