Floating-Support Rolling Tool for Self-Aligning Profile Sections
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Solution Overview
Problem
Existing rolling tools incur high refurbishment costs and compromise the quality of the outer contour of workpieces due to complex designs and material inefficiencies, particularly in the alignment and maintenance of profiling sections.
Innovation Solution
A rolling tool design featuring a base body and profile part connected via a floating bearing with translational degree of freedom, allowing for self-alignment using off-track forces and enabling easy interchangeability and material savings by separating the tool into distinct, differently materialled parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the rolling tool is designed as a multi-part construction with firmly connected base body and profile part, then the structural stability is improved, but the refurbishment costs increase and material efficiency decreases
Solution Approach 1:
The rolling tool is divided into two separable parts: a base body and a profile part. The profile part can be detached and replaced independently when worn, while the base body remains. This segmentation allows cost-effective refurbishment by replacing only the consumable profile part rather than the entire tool assembly.
Solution Approach 2:
The profile part is designed as a consumable component that can be discarded when worn and replaced with a new or reconditioned profile part. The base body is recovered and retained for continued use, reducing material waste and refurbishment costs.
2Strength
If the base body and profile part are firmly connected by screw connections, then the connection strength is improved, but the alignment precision deteriorates due to inability to self-adjust
Solution Approach 1:
The connection between the base body and profile part transitions from a static, fixed connection to a dynamic, adjustable connection. The profile part can move relative to the base body in the rolling direction and automatically align itself during operation, enabling real-time adjustment while maintaining operational strength.
Solution Approach 2:
The profile part performs self-alignment automatically during the rolling process through its ability to move and adjust its position relative to the base body. This self-adjusting mechanism eliminates the need for external alignment procedures or complex adjustment mechanisms.
3Strength
If the profile part has considerable thickness many times thicker than the base body, then the structural strength is improved, but the material efficiency deteriorates and freight costs increase
Solution Approach 1:
The base body and profile part are made with different thicknesses optimized for their specific functions. The base body has sufficient thickness for structural support and mounting, while the profile part has the minimum necessary thickness for its shaping function. This local optimization reduces overall material consumption while maintaining required strength at each location.
4Device complexity
If the rolling tool is designed as a single integrated piece, then the device complexity is reduced, but the adaptability deteriorates for different material requirements and functions
Solution Approach 1:
The rolling tool is segmented into a base body and a profile part that can be independently selected and combined. Different profile parts can be attached to the same base body to create tools suited for different materials and functions, providing versatility without requiring multiple complete tool assemblies.
Solution Approach 2:
The base body is designed as a universal mounting platform that can accommodate different profile parts. This allows a single base body to serve multiple functions by simply changing the profile part, reducing the need for multiple specialized tools while maintaining adaptability to different workpiece requirements.
Data Source
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AI summary
A rolling tool (5) has a main body (6) for fastening of the rolling tool (5) in a rolling machine (1) and a profiled part (7) for the shaping treatment of a workpiece (2) to be rolled. The main body (6) and the profiled part (7) have a multi-piece design. The main body (6) and the profiled part (7), when connected to each other, are mounted so as to be movable relative to each other in a plane perpendicular to the rolling direction (23). The main body (6) of the rolling tool (5) can also be part of the rolling machine (1).