Long-Product Rolling with Interstand Tension and Fewer Stands
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Solution Overview
Problem
The existing rolling processes for long products require numerous stands and significant time and power expenditure to achieve the desired reduction in section, as compression rolling is the only process that guarantees acceptable productivity, leading to inefficiencies and economic disadvantages.
Innovation Solution
A rolling process that applies a tensile load between two stands to achieve single-axis deformation greater than 0.1 in the rolling direction, combined with compression deformation between the rolls, reducing the cross-sectional area by at least 5%, and uses spacer elements to offset tensile loads and prevent flexural stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compression rolling is used to reduce section, then productivity is maintained at acceptable levels, but the number of stands required increases and time and power expenditure increase significantly
Solution Approach 1:
The patent inverts the conventional compression-only rolling approach by introducing a tensile load between stands. This creates a combined tensile-compression process where the tensile load generates single-axis deformation (strain > 0.1) that reduces the cross-sectional area, allowing fewer stands to achieve the same section reduction that would otherwise require multiple compression stands.
Solution Approach 2:
The patent changes the deformation mode parameter from pure compression to combined tensile-compression by applying a tensile load between stands. This parameter change enables single-axis deformation greater than 0.1, which significantly reduces the number of stands needed while maintaining productivity, as the tensile component contributes directly to section reduction.
2Manufacturing precision
If multiple stands are used to achieve section reduction, then the desired reduction is achieved, but time expenditure and power consumption increase
Solution Approach 1:
By inverting the conventional approach and applying tensile load between stands, the patent achieves section reduction more efficiently. The tensile load creates single-axis deformation that directly reduces cross-sectional area, allowing the desired section reduction to be achieved in fewer stands and less time compared to sequential compression rolling.
Solution Approach 2:
The patent merges tensile and compression deformation modes into a single integrated process. The tensile load between stands and compression between rolls work together to achieve section reduction, combining the benefits of both deformation modes to reduce the number of processing steps and overall processing time.
3Productivity
If tensile load is applied between stands, then the number of stands needed is reduced and productivity increases, but flexural stresses may damage the product
Solution Approach 1:
The patent introduces spacer elements as intermediary components between the rolling stands. These spacers offset the tensile load applied between stands, preventing the development of harmful flexural stresses in the product while allowing the tensile-compression deformation to proceed. This mediator enables the productivity benefits of tensile loading without the damaging side effects.
4Reliability
If section reduction is achieved through multiple compression stands, then the process is reliable, but power expenditure increases significantly
Solution Approach 1:
The patent changes the energy efficiency parameter by introducing tensile load between stands. The combined tensile-compression process achieves section reduction with lower total power expenditure compared to multiple compression stands, while maintaining process reliability through the controlled application of tensile load and use of spacer elements to prevent damage.
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 reduces the number of stands needed and increases productivity by achieving the desired section reduction with fewer runs, while maintaining material integrity and preventing surface damage, thus enhancing economic and operational efficiency.
Implementation Method 1
the rolled stock is subjected to a tensile load, between the two stands, which generates a single-axis deformation, or strain ε, greater than 0.1 in the rolling direction
Implementation Method 2
deformed by compression between the rolls of at least one rolling mill stand in the said pair, thereby achieving a reduction in the area of the cross section of at least 5%
Implementation Method 3
The rotation speed of the cylinders in each stand is adjusted appropriately based on the section of the product in the specific stand and ensures the product is driven through the mill as a result of the friction applied thereto by the cylinders
Data Source
AI summary
A rolling process for long solid-section products includes the steps of rolling stock through a plurality of rolling mill stands, the rolled stock being subjected to a tensile load, between the plurality of stands, that generates a single-axial deformation greater than 0.1 in the rolling direction, and is also deformed by compression between the rolls of at least one of the rolling mill stands, thereby achieving a reduction in the cross section area of at least 5%, preferably of between 5 and 50%. A rolling mill, in which a plurality of stands is connected by spacer elements designed to offset the tensile load; a rolling mill, in which a plurality of stands is connected by elements designed to offset the overturning moment generated by the tensile load; and a rolling mill, in which the aforesaid rolling stands maintain a non-slip condition.