Eccentric Tool Ring Compression Rolling for Complex Wheel Profiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming vehicle wheels from hollow cylindrical or truncated cone-shaped workpieces face limitations due to the need for an inner roller carrier that protrudes into the workpiece, restricting the radius of the inner pressure roller and requiring complex clamping systems.
Innovation Solution
A method and device utilizing a radially adjustable eccentric tool ring with its own axis of rotation, positioned outside the workpiece, allowing for larger radius adjustment and eliminating the need for an inner support, combined with a CNC-controlled system for precise forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an inner roller carrier is used to support the inner pressure roller, then the inner pressure roller can be positioned and adjusted, but the radius of the inner pressure roller must be relatively small due to limited space within the workpiece
Solution Approach 1:
The invention extracts the support function from the inner roller carrier that protrudes into the workpiece and relocates it to an outer support structure. The inner roller carrier is removed entirely, and the eccentric tool ring is supported from the outside, allowing the inner pressure roller to have a larger radius without interfering with workpiece accommodation space.
Solution Approach 2:
The invention changes the spatial arrangement by moving the support structure from inside the workpiece to outside the workpiece. The eccentric tool ring is supported from the radial outer side, transforming the support dimension from internal to external, which resolves the space constraint issue.
2Ease of manufacture
If an inner roller carrier projects into the workpiece to accommodate pressure rollers, then pressure rolling can be performed, but the clamping system becomes more complex
Solution Approach 1:
The invention removes the complex inner roller carrier structure that projects into the workpiece and replaces it with a simpler outer support structure. The clamping system no longer needs to accommodate and adjust internal carrier components, reducing overall system complexity while maintaining pressure rolling functionality.
3Volume of moving object
If the inner pressure roller radius is limited to accommodate the roller carrier, then the carrier fits within the workpiece, but the forming capability for complex profiles is restricted
Solution Approach 1:
By removing the space-consuming inner roller carrier and supporting the eccentric tool ring from the outside, the invention maximizes the available volume within the workpiece while enabling the use of larger radius pressure rollers that provide better forming capability for complex wheel profiles.
Solution Approach 2:
The invention introduces radial adjustability of the eccentric tool ring, allowing dynamic adaptation of the forming radius and profile. This enables the same tooling setup to form wheels with different dimensions and complex profiles by adjusting the radial position of the eccentric tool ring.
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a process and a device for compression rolling a workpiece (W), at least some parts of which have the shape of a hollow cylinder or a hollow truncated cone and which is formed into a vehicle wheel by the compression rolling process. In order to compression roll the workpiece on a rotatable main spindle with a main spindle mount (2) of a compression rolling device, the workpiece (W) is axially clamped between the main spindle with the main spindle mount (2) and a setter (3) and is rotated about the main rotational axis (HA) of the main spindle by means of the main spindle with the main spindle mount (2). The compression rolling process is carried out by means of at least one compression roll (4) arranged radially outside of the hollow cylindrical or hollow truncated cone-shaped workpiece (W). The invention is characterized in that a radially inner rotatable eccentric tool ring (5) is arranged radially within the workpiece (W) as a counter bearing for the workpiece (W) during the compression rolling process, said eccentric tool ring being at least radially movable and having a dedicated rotational axis (5A) which can be moved radially in parallel to the main rotational axis (HA) between a first position and a second compression rolling position that is radially offset to the first position. In the compression rolling position, the main rotational axis (HA) of the main spindle with the main spindle mount (2) also lies radially within the bore or the inner diameter of the eccentric tool ring (5) but is no longer aligned with the dedicated rotational axis (5A) of the eccentric tool ring (5).