Rolling Device Mandrel Segmentation for Multi-Workpiece Processing
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Solution Overview
Problem
Conventional rolling processing devices face challenges in producing annular members for rolling bearings, particularly when forming three or more workpieces simultaneously, as this increases the load on the mandrel, leading to a higher risk of breakage due to increased bending moments.
Innovation Solution
A rolling processing device and method that utilize disc-shaped protrusions on forming and support rolls to distribute the forming force evenly, allowing for the simultaneous rolling of three or more workpieces while reducing the bending moment on the mandrel by alternately arranging workpieces and using a configuration that mimics the support of a single workpiece, thereby preventing mandrel breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If three or more workpieces are rolled simultaneously, then productivity is improved, but the bending moment on the mandrel increases leading to higher breakage risk
Solution Approach 1:
The mandrel is divided into multiple separate mandrels, each supporting a subset of workpieces. This segmentation distributes the bending moment across individual mandrels rather than concentrating it on a single mandrel, allowing simultaneous processing of three or more workpieces without exceeding the strength limits of each mandrel.
2Device complexity
If multiple workpieces are arranged on a single mandrel, then device complexity is reduced, but the bending moment increases causing mandrel breakage
Solution Approach 1:
The single mandrel is segmented into multiple mandrels that are arranged in parallel. Each mandrel independently supports one or more workpieces, thereby reducing the bending moment on each individual mandrel while maintaining the capability to process multiple workpieces simultaneously.
Solution Approach 2:
The arrangement of mandrels transitions from a single linear arrangement to a multi-dimensional configuration where multiple mandrels are positioned side by side. This spatial distribution in another dimension allows the system to handle multiple workpieces without overloading any single mandrel.
3Device complexity
If the distance between support points is increased to accommodate multiple workpieces, then device complexity is reduced, but the bending moment on the mandrel increases
Solution Approach 1:
The support structure is segmented into multiple independent mandrels, each with its own support points. This allows the distance between support points to remain optimized for each individual mandrel while accommodating multiple workpieces across the segmented system, preventing excessive bending moments.
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
Enables the efficient production of annular members by rolling-forming multiple workpieces at once without significantly increasing the risk of mandrel breakage, maintaining productivity comparable to single-workpiece processing while allowing for compact device design.
Implementation Method 1
a rolling processing device for rolling-forming three or more cylindrical members (4) at the same time to produce annular members (2)
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
A rolling processing device and a rolling processing method are provided to be capable of producing annular members by rolling-forming three or more cylindrical members at the same time while reducing the possibility of breakage of a mandrel. For this purpose, a rolling processing device (1) includes a forming roll (10), a support roll (20), and a mandrel (30). Plural workpieces (4) are arranged on the mandrel (30) alternately in the radial direction of the mandrel (30). The rolling processing method includes an arranging process for arranging the workpieces (4) on the mandrel (30) and a rolling process.