Interchangeable Rolling Disc Assembly for Longer Tool Life
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Solution Overview
Problem
Existing rolling machines have a low service life and high maintenance costs due to the complex production of rolling tool profiles by grinding, leading to frequent replacements of rolling discs or entire machines.
Innovation Solution
A rolling tool and process featuring a roller disc package with a main disc and an interchangeable alternating disc, where the alternating disc performs the majority of the forming work and can be easily exchanged when worn, reducing material waste and extending tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rolling tool profiles are produced by grinding, then the manufacturing precision is improved, but the manufacturing cost and service life are worsened due to complex production processes and frequent replacements
Solution Approach 1:
The rolling tool is divided into a main disk and an interchangeable disk that can be separately manufactured and replaced. The interchangeable disk contains the profiled rolling surface that contacts the workpiece, while the main disk provides structural support. This segmentation allows the expensive profiled surface to be manufactured once on a master tool and then replicated on multiple interchangeable disks, reducing overall manufacturing complexity and cost while maintaining precision.
Solution Approach 2:
The interchangeable disk is designed to be replaceable when worn, allowing the valuable profiled geometry to be preserved on the main disk while only the consumable portion is discarded and replaced. This extends the service life of the rolling tool assembly and reduces the frequency of complete tool replacements, addressing the service life issue mentioned in the contradiction.
2Duration of action of stationary object
If the interchangeable disc performs the majority of forming work, then the service life of the main disc is extended, but the complexity of the rolling tool assembly increases
Solution Approach 1:
The rolling tool is segmented into a main disk and an interchangeable disk mounted on its front side. The interchangeable disk is specifically designed to perform the majority of the forming work on the workpiece, while the main disk provides structural support and mounting functionality. This clear functional segmentation extends the service life of the expensive main disk while keeping the overall assembly relatively simple through standardized mounting interfaces.
3Productivity
If round rolling tools are used to apply profile to workpiece, then the productivity is improved, but the pressure on workpiece becomes excessively high leading to cracking and distortion
Solution Approach 1:
The interchangeable disk is designed with a specific profile geometry that distributes the rolling pressure more evenly across the workpiece surface. The profile includes a gradual transition zone that reduces stress concentration at the entry point, and the disk geometry is optimized to apply force distributed over a larger contact area, preventing excessive localized pressure that causes cracking and distortion while maintaining high productivity.
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 extends the service life of rolling tools, reduces material waste, and lowers maintenance costs by allowing the interchangeable disc to be replaced without replacing the entire machine, while maintaining efficient rolling processes for both short and long workpieces.
Implementation Method 1
a rolling disk assembly (14) having at least one main disk (24) and an interchangeable disk (26) releasably and non-rotatably attached thereto
Implementation Method 2
The interchangeable disk (26) is positioned upstream of the main disk (24) with respect to a working direction (8)
Implementation Method 3
When the rolling tool is operated in the rolling machine, the interchangeable disk (26) first encounters the workpiece (4) and is primarily subjected to this stress
Implementation Method 4
a rolling tool for rolling a profile, in particular a spline on a workpiece, and a corresponding method therefor
Data Source
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AI summary
The invention relates to a rolling tool (10) for rolling a profile, in particular a spline toothing on a workpiece using a rolling disc packet, comprising at least one main disc (24) and an exchangeable disc (26) secured thereon. According to the invention, the exchangeable disc (26) has a phase (40) or a profile depression (42) in the working direction (8). The invention also relates to a method for rolling a profile, in particular a spline toothing on a workpiece.