Hollow Embossing Rolls for Precise Simultaneous Cutting
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Solution Overview
Problem
Current technologies face challenges in producing workpieces with complex structures, such as marginal sections and internal cutouts, while minimizing deformations and ridge formation, and are not suitable for mass production due to quality issues and high production costs.
Innovation Solution
A roller machine with a pair of rollers that combine embossing and cutting functions, where one roller acts as a patrician and the other as a matrix, allowing for simultaneous shaping and cutting of band-shaped components with precisely aligned embossing and cutting contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate embossing and cutting machines are used, then each process can be performed independently, but the alignment between embossing contour and cutting contour becomes very complex and misalignment occurs frequently
Solution Approach 1:
The patent combines the embossing and cutting functions into a single rolling machine with integrated male and female dies. The male die includes both an embossing contour and a cutting contour, while the female die has corresponding recesses. This integration eliminates the need for separate machines and ensures precise alignment between embossing and cutting operations, as both processes occur simultaneously within the same tooling assembly.
2Shape
If complex surface structures are produced by material removal processes, then the desired structures can be achieved, but the production becomes labor- and energy-intensive
Solution Approach 1:
Instead of creating complex surface structures on rollers through labor-intensive material removal processes like milling and grinding, the patent inverts the approach by forming the embossing and cutting contours directly into the male and female dies during tooling fabrication. The complex geometries are built up or formed in the die cavities themselves, eliminating the need for subsequent roller surface modification and significantly reducing manufacturing complexity and cost.
3Ease of manufacture
If separate male and female tools are used for embossing and cutting, then each tool can be optimized independently, but the tolerance in fit of joined parts reduces quality during continuous operation
Solution Approach 1:
The patent merges the embossing and cutting functions into integrated male and female die assemblies where both functions are built into single tooling units. The male die contains both the embossing protrusion and the cutting edge, while the female die has corresponding recesses and counter-forms. This integration ensures that the relative positions and tolerances between embossing and cutting features are maintained throughout continuous operation, eliminating quality degradation that occurs with separate tools.
4Shape
If traditional rolling processes are used, then simple shaping can be achieved, but complex structures such as edge cutouts and internal cutouts with simultaneous 3D embossing cannot be produced
Solution Approach 1:
The patent creates a universal rolling machine system where the male and female dies can be configured with various combinations of embossing contours and cutting contours. The same basic tooling structure can produce simple or complex geometries including edge cutouts, internal cutouts, and 3D embossed features simultaneously. This multi-functional capability allows a single machine to handle a wide range of workpiece designs without requiring specialized equipment for each geometry type.
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 enables the production of high-quality, deformation-minimized workpieces with complex geometries, reducing the need for additional exemption work and improving mass production capabilities by ensuring precise alignment of embossing and cutting contours.
Implementation Method 1
These generally involve cold sheet forming processes, specifically longitudinal rolling processes
Implementation Method 2
The embossing and cutting contour is designed to produce elevations in the workpieces relative to the plate plane
Implementation Method 3
The rolling machine advantageously enables the simultaneous embossing and cutting of workpieces through a combined rolling and cutting process
Data Source
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AI summary
The invention relates to a rolling machine and a method for hollow embossing and cutting rolling, with at least one pair of rollers comprising two rolling tools, which defines a rolling gap between them, wherein one of the rolling tools initially has an embossing and cutting contour in order to enable embossing and cutting of workpieces from a strip-shaped starting material as they pass through the rolling gap.