Ring Rolling Induction Heating for Uniform Temperature Control
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Solution Overview
Problem
In ring rolling, controlling the temperature distribution of the ring material within the appropriate range is challenging due to variations in the distance between the induction heating coil and the ring material, leading to inconsistencies in temperature across the inner and outer circumferential regions, which affects the dimensional accuracy and quality of the ring-rolled product.
Innovation Solution
A method using a rolling device with a mandrel roll, main roll, and at least one induction heating element, where the induction heating element is positioned on the outer circumferential side and inclined relative to the ring material's circumferential or axial direction, allowing for efficient temperature control by adjusting its position and orientation to maintain uniform temperature distribution during the rolling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an induction heating coil surrounds the entire circumference of the ring material cross-section, then the ring material can be heated, but the distance between the heating coil and ring material changes during deformation making temperature control difficult
Solution Approach 1:
The induction heating system is divided into multiple independent heating zones: a first induction heating coil for the inner circumferential surface and a second induction heating coil for the outer circumferential surface. This segmentation allows independent temperature control of different regions, compensating for distance variations during ring deformation and maintaining uniform temperature distribution throughout the ring material.
Solution Approach 2:
Different induction heating coils are applied to different regions of the ring material based on their specific heating requirements. The inner circumferential surface receives heating from the first coil while the outer circumferential surface receives heating from the second coil, allowing localized temperature optimization for each region despite varying distances from the heating sources.
2Productivity
If the ring material is heated in advance, then the ring rolling process can proceed, but temperature decreases during rolling affecting quality
Solution Approach 1:
The induction heating coils operate continuously throughout the ring rolling process rather than only in advance. The first and second induction heating coils maintain heating of the inner and outer circumferential surfaces respectively during deformation, ensuring continuous temperature maintenance and preventing quality degradation while the ring rolling proceeds efficiently.
3Temperature
If induction heating is applied to the entire ring material, then heating can be achieved, but temperature distribution uniformity is difficult to control
Solution Approach 1:
The heating system is segmented into multiple independent induction heating coils positioned at different locations and orientations. The first induction heating coil targets the inner circumferential surface while the second coil targets the outer circumferential surface, allowing independent adjustment of heating parameters for each region to achieve uniform overall temperature distribution.
Solution Approach 2:
Each region of the ring material receives customized heating treatment through dedicated induction heating coils. The inner circumferential surface is heated by the first coil with parameters optimized for that region, while the outer circumferential surface is heated by the second coil with region-specific parameters, ensuring uniform temperature distribution across the entire ring material.
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 method effectively controls the temperature distribution of the ring material within the appropriate range, enhancing the dimensional accuracy and quality of the ring-rolled product by ensuring consistent heating across the ring material's surface and interior.
Implementation Method 1
at least one induction heating element which is configured so as to induction-heat the ring material
Data Source
AI summary
A method for manufacturing a ring-rolled product, which manufactures the ring-rolled product from a ring material, includes a step of rolling the ring material, which has an operation of rolling the ring material from both inner and outer circumferential sides thereof between a mandrel roll and a main roll in a state of rotating the ring material toward one side in a circumferential direction thereof, and induction-heating the ring material by induction heating elements. An induction heating element is disposed on only an outer circumferential side of the ring material or is disposed on each of both the inner and outer circumferential sides in a region immediately before the rolling, or an inclined portion is provided in an outer-peripheral edge portion of a coil in the induction heating element.