Pressure Rolling with CNC Inner-Outer Rollers for Variable Wheel Profiles
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Solution Overview
Problem
Existing methods for flow-forming vehicle wheels are limited in flexibility and efficiency, particularly for small quantities, as they require expensive spinning tools and rigid mandrels, restricting the variety of shapes that can be produced.
Innovation Solution
A method and device that allow independent axial and radial movement of inner and outer rollers, controlled by CNC technology, enabling the formation of various wall thickness profiles and contours without the need for specific spinning tools, allowing for the production of a wide range of wheel shapes efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed die or rigid mandrel is used for pressure rolling, then manufacturing precision is maintained, but adaptability to produce various wheel shapes is reduced
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed, rigid forming tools with movable rollers that can be independently positioned in the axial and radial directions. The inner and outer rollers are mounted on supports that allow dynamic adjustment of their positions, enabling the system to adapt to various wheel shapes while maintaining forming precision through controlled material flow.
2Manufacturing precision
If a central die is used to form the inner contour, then manufacturing precision is improved, but device complexity and cost increase due to tool changes
Solution Approach 1:
The patent extracts the die from the forming system and replaces it with movable inner rollers. Instead of using a central die that requires changes for different shapes, the inner contour is formed by the inner rollers that can be independently positioned and adjusted, eliminating the need for complex tool changes while maintaining inner contour precision.
Solution Approach 2:
The inner rollers are mounted on an inner support that allows dynamic adjustment of their axial and radial positions. This dynamic capability enables the system to form various inner contours without requiring physical changes to the tooling, thereby reducing device complexity while maintaining manufacturing precision.
3Manufacturing precision
If outer and inner rollers are fixed at a predetermined distance, then manufacturing precision is maintained, but adaptability to create variable wall thickness profiles is reduced
Solution Approach 1:
The patent applies dynamics by allowing the inner and outer rollers to be independently movable in both axial and radial directions. This independence enables the distance between the rollers to be dynamically adjusted during the forming process, allowing for the creation of variable wall thickness profiles while maintaining precise control over the final dimensions and shape.
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
Enables the flexible and efficient production of vehicle wheels with customizable contours and wall thicknesses, facilitating the creation of complex shapes without the need for costly spinning tools or rigid mandrels, suitable for both small and large quantities.
Implementation Method 1
an axially extending outer surface area of the workpiece is formed under material thinning
Data Source
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AI summary
The invention relates to a method and a device for roll forming, wherein a workpiece is set in rotation by means of a spindle and at least one outer roller is positioned against an outer surface of the workpiece. An axially extending outer surface of the workpiece is formed through material thinning. According to the invention, at least one inner roller is positioned against an inner surface of the workpiece by means of an inner support, which is movable axially and radially to the axis of rotation independently of the outer roller. The inner support with the inner roller and an outer support with the outer roller are moved individually by means of a CNC control, whereby a defined wall thickness profile with different wall thicknesses between the at least one outer roller and the at least one inner roller is formed on the outer surface.