Multi-Roller Bending of Angled Workpieces Without Inner-Side Buckling
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Solution Overview
Problem
Conventional rolling methods result in intensive deformation and buckling at the inner side of the bend radius, leading to reduced shape accuracy and potential distortion or cracking in workpieces with complex cross-sectional shapes, as they struggle to simultaneously roll multiple thickness portions at different angles.
Innovation Solution
A rolling machine and method that utilize multiple roller units to simultaneously roll and bend workpieces with varying thickness portions by adjusting the amount of rolling and stretching along the bend radius, ensuring a larger stretch on the outer side compared to the inner side, thereby preventing intensive deformation and residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional rolling methods are used to bend workpiece material, then the material can be bent into a curved shape, but intensive deformation occurs at the inner side region causing buckling and warpage that reduces shape accuracy
Solution Approach 1:
The patent applies local quality by differentiating the rolling treatment between the inner side and outer side of the bend radius. Different types of rollers are used: compression rollers on the inner side to control buckling, and tension rollers on the outer side to control warpage. This localized differentiation of rolling conditions prevents intensive deformation and maintains shape accuracy throughout the bent workpiece.
2Shape
If conventional rolling methods are used on workpieces with complex cross-sectional shapes (H shape, L shape, channel shape, crank shape), then bending is difficult to achieve, but attempting to roll all thickness portions simultaneously causes distortion and cracking
Solution Approach 1:
The patent segments the rolling process by dividing the workpiece thickness portions into different groups based on their position and orientation. Multiple sets of rollers are assigned to different thickness portions, allowing each portion to be rolled independently with appropriate rolling conditions. This segmentation prevents distortion and cracking by avoiding excessive deformation of any single thickness portion while achieving the desired bent shape.
3Shape
If conventional rolling methods are used on workpieces with multiple thickness portions at different angles, then one surface may be rolled while another remains unrolled, but this results in residual stress and potential cracking
Solution Approach 1:
The patent applies local quality by assigning different rolling treatments to different surfaces of the workpiece. Multiple sets of rollers are positioned to contact and roll different thickness portions simultaneously, with each set adjusted to provide appropriate rolling pressure and deformation control for its specific location. This ensures uniform deformation distribution and minimizes residual stress throughout the workpiece.
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 enhances shape accuracy after bending by evenly distributing deformation across the workpiece, reducing the risk of distortion and residual stress, and allowing for precise thickness control post-bending.
Implementation Method 1
a degree of compression and deformation in a region corresponding to an inner peripheral side of the bend radius
Implementation Method 2
a degree of tension and deformation in a region corresponding to an outer peripheral side of the bend radius
Implementation Method 3
the material undergoes deformation intensively in the inner side region
Data Source
AI summary
A workpiece material is fed between rollers to bend the workpiece material while rolling, wherein the workpiece has a first thickness portion and a second thickness portion connected to each other with a setting angle of 90 degrees. The first thickness portion increases from an inner side toward an outer side, and a thickness on an outer peripheral side of the first thickness portion is M, and a thickness of a cross section of the second thickness portion is N. The workpiece material is rolled in such that at a completion of bending, a thickness of a cross section of a first thickness portion is m, an outer radius of the first thickness portion is R, an inner radius of the first thickness portion is r, and a thickness of a cross section of a second thickness portion is n, and M equals to m(R/r), and N equals to n(R/r).