Induction-Heated Main Roll for Ring Rolling Temperature Control
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Solution Overview
Problem
In ring rolling, controlling the temperature distribution of the ring material within the appropriate range is challenging due to changes in the distance between the induction heating coil and the ring material, leading to reduced dimensional accuracy and potential cracking, especially when heating dies insufficiently and uneven temperature distribution across the ring material's circumference.
Innovation Solution
The method involves using a mandrel roll and a main roll that are induction-heated by at least one induction heating element, allowing for precise control of the ring material's temperature distribution during rolling by maintaining the main roll's temperature within a specific range to prevent heat transfer-induced temperature drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an induction heating coil is used to heat the ring material during ring rolling, then the temperature of the ring material can be maintained, but the distance between the induction heating coil and the ring material changes due to deformation, making it difficult to control the temperature distribution
Solution Approach 1:
The patent introduces the main roll as an intermediary heating medium. Instead of directly heating the ring material with an induction coil, the induction coil heats the main roll, which then transfers heat to the ring material through contact. This mediator approach solves the control problem because the main roll's rotation speed and contact pressure can be precisely controlled, ensuring uniform heat transfer even as the ring material deforms.
Solution Approach 2:
The patent replaces the direct electromagnetic heating system (induction coil facing the ring) with a combined thermal-mechanical system (induction-heated main roll contacting the ring). This substitution allows the use of mechanical control parameters (rotation speed, contact pressure) to achieve more precise temperature distribution control compared to direct electromagnetic heating.
2Temperature
If the ring material is heated in advance and then rolled, then the initial temperature can be maintained, but the temperature decreases during the rolling process, reducing dimensional accuracy
Solution Approach 1:
The patent implements continuous heating during the rolling process by rotating the induction-heated main roll in contact with the ring material. This ensures that heat is continuously supplied to the ring material throughout the deformation process, preventing temperature drop and maintaining dimensional accuracy. The heating action continues uninterrupted as the ring rotates and deforms.
Solution Approach 2:
The main roll is induction-heated in advance before contacting the ring material. This preliminary heating of the rolling tool ensures that heat is immediately available when the rolling process begins, preventing initial temperature drops and ensuring the ring material maintains its temperature throughout the deformation process.
3Temperature
If induction heating is applied to the entire circumference of the ring material, then uniform heating is achieved, but the distance variation during deformation makes temperature control difficult
Solution Approach 1:
The main roll serves as a mediator that distributes heat uniformly around the ring material's circumference through rotation and contact. This approach achieves uniform heating without requiring a complex multi-zone induction coil system, as the rotating main roll naturally distributes heat evenly as it contacts different portions of the ring during rotation.
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 approach efficiently controls the temperature distribution of the ring material, enhancing the quality and dimensional accuracy of the ring-rolled product by maintaining consistent heating and preventing temperature-related defects.
Implementation Method 1
a step of rolling the ring material, the rolling including an operation of induction-heating the main roll by at least one induction heating element
Data Source
AI summary
A method for manufacturing a ring-rolled product forms the ring-rolled product from a ring material by using a mandrel roll and a main roll. The mandrel roll and the main roll are configured so as to contact inner and outer circumferential surfaces of the ring material, respectively, and are configured so as to press the ring material in a radial direction thereof in a state in which the ring material is rotated in a circumferential direction thereof. The method includes a step of rolling the ring material that includes an operation of induction-heating the main roll by at least one induction heating element and rolling the ring material between the mandrel roll and the main roll, which is induction-heated.