Hollow Shaft Pressure Rolling with Single-Holder End Profiling
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Solution Overview
Problem
Existing methods for producing hollow shafts through pressure rolling are complex and require multiple workpiece holders, limiting the process to tubular preforms and preventing continuous forming due to the need for frequent adjustments and the inability to handle various cross-sectional shapes.
Innovation Solution
Introducing external and/or internal profiling at both ends of the tubular preform with force-fitting or form-fitting mandrels, allowing the entire forming process to be conducted continuously using a single workpiece holder and enabling the use of preforms with round or polygonal cross-sections, while maintaining the middle area unchanged for accommodating winding packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple workpiece holders are used for different process steps, then the preform can be formed in different regions, but the process becomes complex and cannot run continuously
Solution Approach 1:
A single workpiece holder is designed to perform multiple functions by sequentially positioning the preform for different forming operations. The holder can accommodate both the central tube region and end regions during different process steps, eliminating the need for multiple specialized holders while maintaining the capability to form various regions of the preform.
Solution Approach 2:
The workpiece holder is designed with adjustable and reconfigurable features that allow it to dynamically adapt its positioning and clamping configuration for different process steps. This enables the same holder to effectively perform the roles of multiple static holders, allowing continuous operation without changing physical hardware.
2Adaptability or versatility
If workpiece holder is changed between process steps, then different regions can be formed, but adjustments are required which interrupt continuity
Solution Approach 1:
The single workpiece holder is designed with multi-functional capabilities that allow it to handle both central region forming and end region forming without requiring physical replacement. The holder incorporates adjustable positioning mechanisms and reconfigurable clamping systems that can be quickly adjusted between different forming operations, eliminating time losses associated with changing holders.
3Adaptability or versatility
If tubular preforms with round cross-section are used, then flow-forming can be applied, but polygonal cross-sections cannot be processed
Solution Approach 1:
The forming apparatus is designed with universal tooling capabilities that can accommodate both round and polygonal cross-sectional preforms. The workpiece holder and forming rolls are configured to adapt to different geometric shapes, allowing the same equipment to process various cross-section types without requiring specialized tooling for each shape.
Solution Approach 2:
The forming process parameters such as roll geometry, clamping force distribution, and heating parameters can be adjusted to suit different cross-sectional shapes. This flexibility in parameter modification enables the apparatus to effectively form both round and polygonal preforms using the same fundamental flow-forming mechanism.
4Productivity
If the central tube region is formed, then the hollow shaft is complete, but winding packages cannot be accommodated without further forming
Solution Approach 1:
The hollow shaft is produced with non-uniform properties along its length: the end regions are fully formed with rotationally symmetric profiles suitable for mounting, while the central tube region is deliberately left in its original polygonal or round cross-section state. This local differentiation allows the central section to naturally accommodate winding packages of electric motors without requiring additional forming operations, while the ends provide structural completeness and mounting capability.
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
Enables continuous forming of hollow shafts with various cross-sectional shapes, reducing the need for adjustments and allowing for the production of hollow shafts suitable for diverse applications, such as electric motor components, with the ability to create stepped ends and internal/external profiling.
Implementation Method 1
During the respective forming process, the preform is set in rotation relative to at least one forming roller, for which purpose the workpiece holder with the preform and/or the at least one forming roller is driven
Implementation Method 2
The heat can be generated inductively, for example, and this heat application can simultaneously harden the component
Implementation Method 3
this heat application can simultaneously harden the component
Data Source
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AI summary
The invention relates to a method for producing a hollow shaft from a tubular preform by means of pressure rolling, wherein each end of the preform is shaped using at least one forming roller, a tubular preform (1) with a round or polygonal cross-section is used, and the preform (1) is held on a workpiece holder (2) in the central tube region (1a) during the entire production process until the hollow shaft is completed.