Hat-Shaped Steel Sheet Pile Hot Forming to Prevent Flange Wave
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Solution Overview
Problem
The existing production methods for hat-shaped steel sheet piles face inefficiencies due to the need for multiple calibers and rolling passes, leading to increased production time, material temperature loss, and reduced yield, as well as issues with flange wave and twist during rolling, and quality deterioration in cold working processes.
Innovation Solution
A production method involving hot rolling with a single caliber rolling stand and on-line bending forming, where the material is rolled to a height lower than the desired product height, allowing for stable multiple-pass rolling and prevention of flange wave and twist, while maintaining high material temperature for improved forming efficiency and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple calibers and rolling passes are used in conventional hot rolling, then the hat-shaped steel sheet pile can be formed, but production time increases and material temperature is lost
Solution Approach 1:
The forming process is divided into two distinct stages: (1) hot rolling to form a preliminary shape with reduced height, and (2) subsequent bending forming to achieve the final hat-shaped product. This segmentation allows each stage to be optimized independently, reducing the total number of rolling passes required while maintaining forming accuracy.
Solution Approach 2:
The preliminary hot rolling process creates a pre-formed intermediate shape that is closer to the final product geometry than conventional methods. This preliminary action reduces the complexity and duration of subsequent forming operations, thereby decreasing overall production time while preserving material temperature.
2Manufacturing precision
If multiple calibers are used in conventional rolling, then the product shape can be achieved, but the number of rolling stands increases
Solution Approach 1:
The forming process is divided into two distinct stages: (1) hot rolling to form a preliminary shape with reduced height, and (2) subsequent bending forming to achieve the final hat-shaped product. This segmentation allows each stage to be optimized independently, reducing the total number of rolling passes required while maintaining forming accuracy.
Solution Approach 2:
An intermediate pre-formed shape is created during hot rolling that serves as a mediator between the initial rectangular bloom and the final hat-shaped product. This intermediate form simplifies the subsequent bending forming process, allowing the final shape to be achieved with fewer and simpler rolling stands.
3Productivity
If conventional hot rolling is used, then the steel sheet pile can be produced, but flange wave and twist occur during rolling
Solution Approach 1:
The forming process is divided into two distinct stages: (1) hot rolling to form a preliminary shape with reduced height, and (2) subsequent bending forming to achieve the final hat-shaped product. This segmentation allows each stage to be optimized independently, reducing the total number of rolling passes required while maintaining forming accuracy.
Solution Approach 2:
The process changes the forming parameters by performing bending forming at a lower temperature than conventional hot rolling, while maintaining the material above its transformation point. This parameter change allows for better control of flange flatness and reduces the occurrence of flange wave and twist defects.
4Manufacturing precision
If cold working is used after hot rolling, then the final shape can be achieved, but material quality deteriorates
Solution Approach 1:
The process changes the forming parameters by performing bending forming at a lower temperature than conventional hot rolling, while maintaining the material above its transformation point. This parameter change allows for better control of flange flatness and reduces the occurrence of flange wave and twist defects.
Solution Approach 2:
Instead of using cold working which deteriorates material quality, the invention utilizes controlled hot bending forming that maintains material temperature above the transformation point. This converts the potential harm of high temperature into a benefit by preserving material ductility and quality while achieving the desired final shape.
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
This method reduces production time and costs, enhances yield, and stabilizes the rolling process by preventing flange wave and twist, while maintaining high material quality through continuous hot rolling and bending forming.
Implementation Method 1
a production method involving hot rolling with a single caliber rolling stand and on-line bending forming, where the material is rolled to a height lower than the desired product height
Implementation Method 2
maintaining high material temperature for improved forming efficiency and quality
Data Source
AI summary
There is provided a production method for a hat-shaped steel sheet pile including performing rough rolling, intermediate rolling, and finish rolling on a material to be rolled through hot rolling, and then performing bending forming, in which the material to be rolled is composed of a web corresponding part, flange corresponding parts, arm corresponding parts, and joint corresponding parts, corner parts as worked parts are formed at connection places between the web corresponding part and the flange corresponding parts and connection places between the flange corresponding parts and the arm corresponding parts, the intermediate rolling is carried out by performing rolling in a plurality of passes on the material to be rolled in a hot state by using a caliber provided to upper and lower caliber rolls in one or a plurality of intermediate rolling mills in which one stand is configured by one caliber, at a height lower than a predetermined target product height, the bending forming is performed in a hot state and performed in a state where the worked parts have a temperature of transformation point or higher, and in the bending forming, the material to be rolled is formed to have predetermined target height and target width.