Roller Forming Regions for Width-Direction Deformation
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Solution Overview
Problem
Existing methods for reducing the thickness of one-piece rolling stock through longitudinal rolling face challenges in material efficiency, as partial thickness reduction in cold rolling leads to internal stresses and warping due to friction and rigidity, and require complex control of forming areas with many passes, resulting in unevenness and high material costs.
Innovation Solution
The method involves forming regions of rollers penetrating to the same depth, creating homogeneous oblique thickness transitions in the width direction, allowing deformation only in the width direction, with forming areas widening the stock towards side edges and using counter-rollers for easy deformation, reducing the number of passes needed for constant depressions and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If forming areas of rollers penetrate to different depths to reduce thickness, then thickness reduction is achieved, but control complexity increases and unevenness occurs
Solution Approach 1:
The patent applies local quality by creating thickness-reduced sections only in specific areas of the rolling stock where material savings are needed, while maintaining constant thickness in other areas. This is achieved through selectively positioned forming areas on rollers that penetrate to the same depth, allowing local thickness modification without affecting the entire cross-section.
Solution Approach 2:
The invention changes the parameter of forming depth from variable (different depths for different sections) to constant (same depth for all forming areas). This parameter standardization simplifies the control system while still achieving the desired thickness reduction in specific sections through the strategic positioning of forming areas.
2Manufacturing precision
If multiple forming passes are used to create constant thickness reduction, then constant depression is achieved, but production time increases
Solution Approach 1:
The patent combines multiple forming functions into a single pass by using multiple rollers with forming areas positioned at different locations along the rolling stock width. All forming areas penetrate to the same depth simultaneously, creating multiple constant thickness-reduced sections in one operation, thereby eliminating the need for multiple sequential passes.
3Loss of substance
If cold rolling is used for thickness reduction, then material efficiency is improved, but internal stresses and warping occur
Solution Approach 1:
The patent minimizes internal stresses and warping by creating localized thickness reductions only in specific sections where needed, rather than attempting to reduce the thickness of the entire cross-section. This localized approach reduces the overall deformation energy and prevents the accumulation of internal stresses that would lead to warping, while still achieving material efficiency in the critical areas.
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 enables efficient material reduction with fewer passes, minimizing internal stresses and warping, achieving a constant depression with improved surface quality and reduced material costs by allowing the rolling stock to be deformed only in the width direction, resulting in a statically advantageous profile with reduced thickness.
Implementation Method 1
the rolling stock is formed in the width direction by laterally offset forming regions of rollers that follow one another in the feed direction
Implementation Method 2
due to the friction transverse to the roll and the rigidity of the flat rolling stock
Data Source
Figure 1~2
Figure 3~4
AI summary
The method involves transforming milling goods (14) by laterally displaced transforming areas (26-29) of rollers (22-25) in a transverse direction (W) into a spreading direction. The transforming areas of the rollers are deeply penetrated into the milling goods, which are widened to two side edges (17, 18) by the transforming areas. The spreading of the milling goods in a plane parallel to a roller axis is carried out by the transforming areas.