Ring-Roll Recessed Main Roll for Stable Ring Material Attitude
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Solution Overview
Problem
The challenge in ring-rolling a ring material with a tapered or uneven thickness shape is stabilizing its attitude during the process, as differences in peripheral speed and diameter lead to unstable rotation, potentially causing defects and increased burden on the rolling device, especially when flange portions are used.
Innovation Solution
The ring-rolling method employs a main roll with a recessed portion and flange portions on the mandrel roll, where the inner faces of the recessed portion have a slope to enlarge the opening, allowing for stable constrainment of the ring material, reducing the need for multiple die patterns and heat treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If flange portions are provided on the main roll to stabilize the attitude of the ring material, then the attitude stability is improved, but defects such as burrs are generated in the resulting ring-rolled member
Solution Approach 1:
The recessed portion is divided into multiple functional zones: a rolling face for deformation, and first/second inner faces with slopes that gradually guide the ring material. This segmentation allows the ring material to be constrained and guided through different zones with appropriate contact characteristics, preventing sudden impacts that cause burrs while maintaining attitude stability.
Solution Approach 2:
The sloped inner faces perform preliminary guidance and positioning of the ring material before it enters the main rolling zone. By gradually constraining the ring material through the sloped surfaces, the system prepares the material for stable rolling without sudden contact or impact, thereby preventing defect formation.
2Stability of the object's composition
If flange portions are provided on the main roll to stabilize the attitude of the ring material, then the attitude stability is improved, but the burden on the ring-rolling device increases
Solution Approach 1:
The recessed portion with sloped inner faces serves multiple functions simultaneously: it guides the ring material, stabilizes its attitude during rolling, and eliminates the need for separate flange portions. This multi-functional design reduces device complexity and burden while achieving the desired attitude stability.
Solution Approach 2:
The stabilizing function traditionally requiring flange portions is extracted and integrated into the recessed portion structure itself. By incorporating the attitude stabilization capability directly into the rolling interface, the need for additional flange structures is eliminated, reducing device burden.
3Adaptability or versatility
If multiple patterns of main roll shapes are prepared to handle different ring material conditions, then the adaptability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Instead of changing the physical structure of the main roll to adapt to different ring material conditions, the invention achieves adaptability through parameter optimization of the recessed portion geometry (slope angles, dimensions). By adjusting these parameters within the same basic structure, the system can handle various ring material shapes and sizes, eliminating the need for multiple die patterns.
4Productivity
If the ring material is heated multiple times to alleviate device burden, then the productivity is reduced, but the device burden is reduced
Solution Approach 1:
The recessed portion with sloped inner faces performs multiple functions in a single heating cycle: guiding the ring material, stabilizing its attitude, and enabling effective rolling. This multi-functionality allows the process to complete in one heating cycle, eliminating the need for multiple heating and rolling cycles, thereby maintaining high productivity while reducing device burden.
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 stabilizes the ring material's attitude during rolling, minimizing defects and reducing the cost and complexity of the process, enabling a nearly net shape ring-rolled member with reduced material input and avoiding excessive contact with axial rolls.
Implementation Method 1
an angle of the slope is greater than 0.3° and no greater than 9° with reference to the perpendicular plane
Implementation Method 2
a first inner face on a side of the first flange portion, and a second inner face on a side of the second flange portion
Data Source
AI summary
Provided is a ring-rolled member manufacturing method enabling stabilization of the attitude of the ring material without generating a defect and the like in the resulting ring-rolled member even when the main roll of the ring-rolling device is provided with the flange portions positioned on upper and lower sides of the ring material. A ring-rolling device used in the ring-rolled member manufacturing method of the present invention is provided with a main roll 10 and a mandrel roll 20. An outer peripheral face of the main roll includes a recessed portion 12 to accommodate the ring material and an outer peripheral face of the mandrel roll 20, an upper flange portion 11 positioned on an upper side thereof, and a lower flange portion 13 positioned on a lower side thereof. An inner face of the recessed portion includes a rolling face 12S to be in contact with an outer peripheral face of the ring material, an upper face on the upper flange portion side, and a lower face 13S on the lower flange portion side, the lower face 13S having a slope in such a way that an opening of the recessed portion 12 is enlarged. The slope starts from within a range of a distance corresponding to a thickness of the ring-rolled member from a line of intersection between the lower face 13S and the rolling face 12S. An angle of the slope is greater than 0.3° and no greater than 9° with reference to the perpendicular plane.