Roll Forming Longitudinally Toothed Pot-Shaped Workpieces
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Solution Overview
Problem
Existing roll-forming processes for producing longitudinally toothed profiled bodies in cylindrical workpieces face issues such as dimensional inaccuracies, material loss, and incomplete tooth formation due to slip between profile rolls and workpieces, as well as the need for complex and costly equipment to maintain synchronization.
Innovation Solution
A roll-forming process that involves a first rolling stage where the workpiece is moved bottom-first with slight over-rolling to maintain cylindrical shape, followed by subsequent rolling stages where the workpiece is moved open-end first to allow material to flow towards the bottom for optimal tooth shaping, reducing material loss and bulging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If profile rolls are freely rotating and pressed into the workpiece, then the roll-forming process is simple, but slip occurs between profile rolls and workpiece causing dimensional inaccuracies
Solution Approach 1:
The patent applies preliminary action by performing an over-rolling operation in the first rolling stage where the tooth crowns are rolled to a specified slight extent before the final forming. This preliminary deformation prepares the material and establishes initial geometric relationships, ensuring that subsequent forming stages produce accurate dimensional features without slip-related errors.
Solution Approach 2:
The roll-forming process is segmented into multiple distinct stages: a first rolling stage with bottom-first movement and over-rolling, followed by subsequent rolling stages with open-end first movement. This segmentation allows each stage to perform a specific function - the first stage prepares the material and prevents bulging, while subsequent stages complete the tooth formation with high precision, thereby resolving the contradiction between process simplicity and manufacturing accuracy.
2Productivity
If roll-forming begins at the pot bottom, then material flows from crown to flanks, but tooth shaping in the pot bottom area becomes deficient
Solution Approach 1:
The patent applies inversion by reversing the conventional roll-forming sequence. Instead of starting at the pot bottom and moving upward, the workpiece is moved bottom-first in the first rolling stage, allowing the profile rolls to contact and form teeth starting from the bottom area. This inverted approach ensures proper material flow and complete tooth shaping in the pot bottom region, resolving the deficiency in traditional methods.
3Device complexity
If profile rolls press into material without pre-forming, then the process is straightforward, but material accumulations are insufficient causing poor profile bearing ratios
Solution Approach 1:
The first rolling stage performs preliminary action by rolling the workpiece bottom-first to create controlled material accumulations in the corner areas and establish proper sheet thickness distribution. This preliminary material redistribution ensures that when subsequent rolling stages form the final tooth profile, adequate material is available at critical locations, achieving optimal profile bearing ratios without requiring complex pre-forming equipment.
4Ease of operation
If the workpiece is moved through rolling stages, then teeth are formed, but material retraction occurs at the tooth crown reducing useful profile
Solution Approach 1:
The over-rolling performed in the first rolling stage serves as preliminary action that prevents material retraction at the tooth crown. By rolling the tooth crowns to a specified slight extent in advance, the material is pre-compressed and stabilized, so that during subsequent forming stages material flows properly without retracting from the crown area, thereby maximizing the useful profile length.
Solution Approach 2:
The patent applies beforehand cushioning by creating excess material accumulation in the corner areas during the first rolling stage. This accumulated material acts as a cushion that compensates for material retraction tendencies during subsequent tooth formation, ensuring that the tooth crowns maintain full material support and achieve maximum useful profile without loss of substance.
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 process optimizes tooth formation at the bottom of the workpiece while minimizing material retraction at the tooth crown, maintaining the same number of rolling stages as prior methods but improving the structural integrity and reducing the structural length and weight of the disk carrier.
Implementation Method 1
a rolling process is carried out, in which, along the periphery of the workpiece being processed, profile rolls arranged regularly and at a uniform angle relative to one another press the desired outer profile into the external surface of the workpiece
Implementation Method 2
the rotation and thus rolling of the profile rolls is produced only by the forces, acting during the deformation, between a workpiece and a profile roll
Data Source
AI summary
A roll-forming process for producing longitudinally toothed profiled bodies in a pot-shaped cylindrical workpiece in which, during a first rolling process (A), the pot-shaped cylindrical workpiece (1) is moved through a first rolling stage with a bottom (3) of the workpiece being rolled first. During at least one further rolling process (B, C), the workpiece (1) passes through at least one further rolling stage with an open end of the workpiece being rolled first.