Four-Roller Skew Rolling for Jam-Free Superalloy Bar Forming
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Solution Overview
Problem
Existing methods for preparing large-size ultrafine-grained superalloy bars face issues such as rolling jamming, low deformation uniformity, and reduced efficiency due to friction between guide plates and the blank, leading to increased mold wear and decreased production efficiency.
Innovation Solution
A skew rolling assembly with four actively rotating unequal-diameter rollers, arranged around a rolling line, promotes forward metal flow and allows for multi-pass reciprocating rolling, minimizing jamming and enhancing deformation and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two stationary guide plates are used to improve dimensional accuracy, then the dimensional accuracy of rolled bars is improved, but the friction between guide plates and blank obstructs metal flow and causes rolling jamming
Solution Approach 1:
The patent inverts the traditional role of guide plates by making them active rolling tools instead of stationary components. The guide plates are replaced with active rollers that rotate in the rolling direction, converting from a stationary guiding function to an active deformation function that promotes metal flow rather than obstructing it.
Solution Approach 2:
The patent extracts and removes the stationary guide plates from the system entirely, replacing them with active rollers. This eliminates the harmful friction effect while preserving the guiding function through the rotational motion and positioning of the active rollers.
2Shape
If redundant metals expand towards the guide plate direction, then metal flow is redirected, but friction resistance increases and rolling jamming occurs
Solution Approach 1:
The patent inverts the interaction between metal flow and guiding components by replacing stationary guide plates with active rollers. The active rollers rotate in the rolling direction, converting the guiding function into a flow-promoting mechanism that reduces friction resistance instead of increasing it.
3Manufacturing precision
If metal contacts the guide plate, then dimensional control is improved, but heat dissipation increases and fluidity worsens
Solution Approach 1:
The patent removes the stationary guide plates that cause excessive heat dissipation and replaces them with active rollers. The active rollers provide dimensional control through their rotational motion and positioning, while minimizing harmful thermal contact and heat dissipation.
4Productivity
If four active rollers are used instead of two rollers with guide plates, then rolling speed and efficiency are improved, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by making all four rollers active and capable of rotation, where each roller simultaneously performs deformation, guiding, and flow-promoting functions. This eliminates the need for separate stationary guide plates, and while the roller configuration is more complex, the overall system is simplified by removing the guide plate components.
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 assembly improves rolling speed and efficiency by avoiding guide plate obstruction, increasing deformation, and reducing forming load, ensuring smooth production of large-size superalloy bars.
Implementation Method 1
the friction between the two guide plates and the blank obstructs the forward flow of the metal in the rolling direction
Implementation Method 2
the metal in contact with the guide plate dissipates heat quickly, and its fluidity becomes worse with the decrease of temperature
Data Source
AI summary
Disclosed is a skew rolling assembly suitable for large-size superalloy bars, including four rollers with completely identical shape and size, where the four rollers are all active rollers. In the production process, the four rollers play a role in promoting the forward flow of blank metal in a rolling direction, thus avoiding a rolling jamming phenomenon caused by the obstruction of guide plates to the forward flow of the blank in the rolling process of the prior art. The providing of the four rollers improves the rolling speed and increases the degree of deformation. Disclosed is a skew rolling method suitable for large-size superalloy bars. By utilizing the skew rolling assembly suitable for the large-size superalloy bars, and utilizing four rotating active rollers for the skew-rolling forming of bars, the rolling speed is improved, the problem that the cooperative rolling of two rollers and guide plates in the prior art is prone to the phenomenon of rolling jamming is avoided, the forming quality is guaranteed, the rolling production efficiency is improved, and the degree of deformation is increased.