Inclined Roll Stamping for Variable Sections Without Roll Interference
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Solution Overview
Problem
Existing roll forming methods face limitations in expanding the shape range of products due to interference issues when the radius of curvature or height of the variable section is small, leading to shape errors and potential damage to the rolls and material.
Innovation Solution
An apparatus for roll stamping utilizing inclined rotation rolls with fixed positions and angles, featuring oblique forming portions on their surfaces, which allow for a variable sectional shape without complex movement devices, preventing interference and enabling efficient formation of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the radius of curvature of the variable section is small or the height of the variable section is large, then the shape range of the product is expanded, but the rotation rolls interfere with each other and overlap, causing potential damage and preventing product formation
Solution Approach 1:
The patent implements a movable lower rotation roll that can adjust its position dynamically. The lower rotation roll is configured to move in the vertical direction to maintain an appropriate gap with the upper rotation roll during the forming process. This dynamic adjustment prevents roll interference and overlap when forming variable sections with small radius of curvature or large height, thereby resolving the contradiction between expanding shape range and preventing roll damage.
2Manufacturing precision
If the gap between the rolls is smaller than the thickness of the material, then the material is caught between the pair of rolls, but this prevents product formation and may damage the rolls
Solution Approach 1:
The lower rotation roll is designed to move vertically to dynamically adjust the gap between the upper and lower rotation rolls. This movement ensures that the gap remains appropriate relative to the material thickness throughout the forming process, preventing the material from being caught between the rolls while still enabling precise variable section formation.
3Adaptability or versatility
If a flexible roll forming method is used to form variable sections, then a component with variable section may be formed, but warpage occurs in lower and side portions of the material resulting in shape errors
Solution Approach 1:
The patent applies preliminary forming action through the inclined forming surfaces of the rotation rolls. The forming portions on the rotation rolls are designed with specific inclination angles that gradually shape the material before final formation. This preliminary action distributes the forming forces more evenly, preventing warpage in the lower and side portions of the material and reducing shape errors in the final product.
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
Expands the formable product shape range by allowing for variable sections with improved efficiency and precision, reducing shape errors and material breakage, while eliminating the need for complicated rotation roll movement devices.
Implementation Method 1
an inclined roll set including a first rotation roll and a second rotation roll rotating while facing each other... a first forming portion for forming the material is formed on an outer surface of the first rotation roll... a second forming portion for forming the material is formed on an outer surface of the second rotation roll
Data Source
AI summary
An apparatus for roll stamping that is capable of expanding a shape range of a product without limitation due to, for example, a radius of curvature or a height of a variable section includes: an inclined roll set including a first rotation roll and a second rotation roll rotating while facing each other, have fixed positions and angles, and are inclined with respect to a traveling material, in which a first forming portion for forming the material is formed on an outer surface of the first rotation roll, the first forming portion includes a first circumferential groove portion inclined at an oblique angle rather than a right angle with respect to a rotation shaft of the first rotation roll.