Radial Upsetting Roller with Axial Support for Edge Contouring
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Solution Overview
Problem
Existing methods for radial upsetting of circular blanks face issues with significant radial forces leading to buckling, frictional heating, and material microstructure impairment, and are inefficient due to the use of multiple rollers with different flank angles.
Innovation Solution
The method involves using two axial forming rollers with a closer axial distance than the forming groove width to reduce friction by back-compressing the thickened area, and a multifunctional compression roller with radial and axial force capabilities for efficient shaping and folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If radial upsetting is performed with a compression roller, then the outer edge of the blank is compressed to form a thickened area, but considerable radial forces are exerted on the blank causing buckling
Solution Approach 1:
Lateral support rollers are introduced as intermediary elements between the compression roller and the blank. These support rollers provide lateral support to the blank during radial upsetting, preventing buckling of the blank edge while allowing the compression roller to effectively form the thickened area.
Solution Approach 2:
The forming groove on the compression roller is designed with specific local geometries including flank angles and groove base radii that are optimized for different stages of the forming process. The groove profile changes locally to control material flow and reduce radial forces during different phases of upsetting.
2Shape
If radial upsetting is performed with a compression roller, then the thickened area is formed, but considerable friction occurs along the flanks of the forming groove causing frictional heating
Solution Approach 1:
The forming groove parameters are optimized to reduce friction: the groove base radius is set between 0.5-2 times the blank thickness, and flank angles are specifically chosen to control material flow. These parameter changes reduce the contact pressure and sliding friction between the groove flanks and the thickened area, thereby reducing frictional heating and protecting the material microstructure.
3Force
If multiple upsetting rollers with different flank angles are used to reduce loads, then the forming process is improved, but the device complexity and cost increase
Solution Approach 1:
The compression roller is designed with a dynamically optimized forming groove profile that incorporates varying flank angles and groove base radii along its length. This single roller with a complex groove geometry performs the function that would otherwise require multiple simpler rollers, reducing device complexity while maintaining effective load management during the forming process.
Solution Approach 2:
The compression roller serves multiple functions simultaneously: it provides the primary compressive force for forming the thickened area, the forming groove profile controls material flow to reduce radial forces, and the groove geometry minimizes frictional heating. This multi-functional design eliminates the need for separate rollers for each function.
4Stability of the object's composition
If lateral support rollers are used to support the blank, then buckling is prevented, but the rollers also contribute to radial shaping of the edge bead
Solution Approach 1:
The forming groove parameters are specifically optimized to account for the dual role of the support rollers. The groove base radius and flank angles are calculated to achieve the desired final edge contour while considering the shaping contribution from the support rollers, ensuring precise control of the thickened area geometry.
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 frictional wear, heating, and load on the rollers, enabling gentler forming and efficient production of thickened edge contours without cutting, while minimizing the number of tools required.
Implementation Method 1
the outer edge of the blank is compressed to form a thickened area, which is formed into a thickened edge contour in accordance with the forming groove of the upsetting roller
Implementation Method 2
Considerable friction occurs along the flanks of the forming groove due to the different movement between blank and compression roller in the circumferential direction. Correspondingly strong frictional heating can result
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method and a device for producing a formed part (9) from a blank (1), wherein the blank (1) is set into rotation and at least one upsetting roller (50) is radially positioned against an outer edge of the blank (1), the upsetting roller having a circumferential forming groove (56). The outer edge of the blank (1) is upset to form a thickened area, which is shaped into a thickened edge contour according to the forming groove (56) of the upsetting roller (50). During radial upsetting, at least two axial forming rollers (41, 42) are positioned against an outer area of the blank (1), which participate in forming the edge contour.According to the invention, it is provided that the two axial forming rollers (41, 42) are positioned at least in an initial phase of the radial upsetting at the thickened area with an axial forming distance to each other which is smaller than an axial width of the forming groove (56) of the upsetting roller (50), whereby the thickened area is axially re-upset.