Incremental Rotary Rolling Mill With Radial Tools for Precise Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rolling mills for forming tubes and rods lack flexibility and accuracy due to their die-dependent processes, which restricts the ability to achieve precise shaping and incremental reduction of workpieces.
Innovation Solution
A rolling mill system with a radial chuck and motorized tools that move radially and rotate relative to the workpiece, allowing for incremental rotary shaping, along with a programmable controller for precise control of the shaping process and electrical current flow to facilitate deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a die-dependent rolling process is used, then the process structure is simple, but the flexibility and accuracy in shaping workpieces is limited
Solution Approach 1:
The patent applies dynamics by making the tools movable relative to the workpiece axis. The tools can be positioned at different radial distances and angular positions, and their orientation can be adjusted. This dynamic positioning capability allows the same tooling system to perform multiple shaping operations on different workpiece geometries, thereby achieving flexibility without requiring complex die changes.
Solution Approach 2:
The patent implements universality through a multi-functional tooling system where a single set of tools can perform various shaping operations. The tools are designed to work in combination with adjustable positioning mechanisms, allowing them to accommodate different workpiece sizes, shapes, and material types. This universal tooling approach eliminates the need for dedicated dies for each operation, enhancing adaptability while maintaining reasonable system complexity.
2Manufacturing precision
If constant rolling size/shape is used, then the device structure is simple, but the ability to achieve incremental reduction is limited
Solution Approach 1:
The patent achieves incremental reduction through dynamic adjustment of tool positions. The tools can be moved radially inward in controlled steps, with each pass removing a small amount of material. The positioning system allows precise control of radial distance and angular position, enabling accurate incremental shaping. This dynamic step-by-step approach provides manufacturing precision while the programmable control manages the complexity of coordinating multiple adjustment parameters.
Solution Approach 2:
The patent applies preliminary action by pre-programming the tool paths and positioning sequences before the shaping operation begins. The control system stores predetermined sequences for radial positioning, angular orientation, and feed rates. This allows the complex multi-parameter control to be managed through pre-planned sequences, achieving accurate incremental reduction without requiring complex real-time calculations during operation.
3Adaptability or versatility
If radial positioning of tools is not adjustable, then the mechanism is simple, but the precision and flexibility of shaping is reduced
Solution Approach 1:
The patent implements dynamic radial positioning where tools can be moved along the radial direction relative to the workpiece axis. This is achieved through mechanisms that allow independent adjustment of each tool's radial position while maintaining their rotational motion. The dynamic radial adjustment capability enables the system to adapt to different workpiece radii and shaping requirements, providing versatility while the modular mechanism design keeps complexity manageable.
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 system provides greater flexibility and accuracy in shaping tubular or rod-shaped workpieces, enabling precise incremental reduction and shaping with reduced ridges and improved surface smoothness.
Implementation Method 1
a rolling mill for forming tubes and rods... a rolling mill that provides for incremental reduction and shaping of a tubular or rod-shaped workpiece
Implementation Method 2
reduces/shapes the cross section of a tube/rod by a rolling process
Implementation Method 3
a source of electric current and an electrically conductive flow path are provided for flowing electrical current through a workpiece
Data Source
AI summary
A rolling mill system for Incremental rotary shaping of an elongated workpiece is provided that includes first and second workpiece holders. A support frame has a track with the first and second workpiece holders being movably associated with the track, the workpiece holders and an associated workpiece being movable in unison along the track. A radial chuck is mounted to the frame that includes a plurality of jaws that are movable radially inwardly and outwardly. Each jaw has a tool mounted thereto that is rotatable about an axis of rotation, with the axis of rotation of each tool being oriented at a skew angle relative to the longitudinal axis of a workpiece. A source of electric current and an electrically conductive flow path are provided for flowing electrical current through a workpiece. A controller is provided that is configured to control the operation of each of the first motor, second motor and third motor, and to control the flow of current flowing through the tools to the workpiece.