Roll Stamping Sequence for Distortion-Free Variable Cross Sections
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Solution Overview
Problem
Roll stamping methods face issues with undesirable shapes due to residual stress and unbalance of force between cross section changing portions, leading to distortion in molded parts, especially when using high-strength steel.
Innovation Solution
A roll stamping apparatus and method featuring sets of rollers with molding portions that sequentially change the material's cross section, including over-molding rollers with longer circumferential lengths to manage stress and balance forces, along with reverse deformation molding steps to mitigate residual stress, and escape portions to control material flow and molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a roll stamping method is used to produce variable cross-section molded articles, then productivity and adaptability are improved, but residual stress and unbalance of force cause distortion and undesirable shapes
Solution Approach 1:
The roll stamping process is divided into multiple sequential stages with different molding portions. Each stage applies a specific cross-sectional shape to the material in sequence, allowing gradual transformation that reduces residual stress and prevents distortion while maintaining high productivity
Solution Approach 2:
The molding portions are designed to pre-form the material cross-section in advance before final shaping. This preliminary action distributes stress evenly and prevents unbalance of force that would cause distortion in the final product
2Strength
If high-strength steel is used to improve material strength, then product strength is improved, but moldability deteriorates causing material breakage
Solution Approach 1:
The roll stamping apparatus uses rotating rolls with varying molding portions that dynamically adjust the forming pressure and geometry during material passage. This dynamic approach allows high-strength steel to be gradually shaped without sudden stress concentrations that would cause breakage
Solution Approach 2:
The cross-sectional parameters of the molding portions are sequentially changed along the rotation direction of the rolls. This gradual parameter change adapts the forming process to the high-strength steel's properties, improving moldability while maintaining material strength
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
The solution effectively reduces residual stress and unbalance of forces, preventing distortion and ensuring accurate shaping of high-strength steel parts by sequentially changing the material's cross section and employing reverse deformation molding.
Implementation Method 1
sets of rollers rotating while facing each other so as to press opposite surfaces of a material which is continuously supplied to move between the rollers
Implementation Method 2
the respective molding portions of the sets of rollers are formed to sequentially change a cross section of the material in the movement direction of the material
Data Source
AI summary
A roll stamping apparatus includes sets of rollers that rotate while facing each other so as to press opposite surfaces of a material which is continuously supplied to move between the rollers. The sets of rollers have molding portions with a stamping structure applied to outer surfaces so as to mold the material, wherein a plurality of sets of rollers are disposed along a movement direction of the material, the respective molding portions of the sets of rollers are formed to sequentially change a cross section of the material along the movement of the material, and the molding portion of at least one set of rollers before a final set of rollers through which the material finally passes is a set of over-molding rollers having a length in a circumferential direction longer than the molding portions of the final set of rollers.