Combined rolling and extruding method and the device for performing the same
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Solution Overview
Problem
Existing methods for continuous casting and extrusion of metals, such as those described in patents RU2547775, RU2568550, RU2519078, RU2100136, and RU2559615, face issues like temperature instability, poor mechanical properties, high friction leading to tool wear, and defects in the final product due to inadequate temperature control and design limitations, which hinder the production of high-quality long products like bars and wire rods with small cross-sections.
Innovation Solution
A device and method for combined rolling and extruding that includes a rotary mould, grooved and finned rolls with a labyrinth coupling, a temperature control system, and a die with adjustable gaps to prevent steel-to-steel contact, allowing for precise temperature management and reduced friction, thereby improving the uniformity and mechanical properties of the extruded products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If continuous casting is performed at low speed (3.5-6 m/min) to improve temperature control, then temperature stability improves, but productivity decreases
Solution Approach 1:
The patent combines continuous casting with rolling and extrusion operations into an integrated process line. The cast billet is immediately fed into rolling mills and then extrusion presses without interruption, merging multiple deformation processes into a continuous operation that maintains productivity while enabling precise temperature control at each stage.
Solution Approach 2:
The patent implements preliminary heating of the cast billet before rolling and extrusion. By pre-heating the billet to the required temperature range before deformation operations, the system ensures optimal temperature conditions for subsequent processing without requiring slow casting speeds, thus maintaining both productivity and temperature control.
2Loss of energy
If additional supporting rolls are used to guide the metal casting product, then temperature losses are reduced, but device complexity increases
Solution Approach 1:
The patent combines the guiding function with the rolling function by using the rolling mill rolls themselves to guide and deform the metal simultaneously. The rolling passes are designed to provide both directional control and deformation in a single operation, eliminating the need for separate guiding sections and reducing overall system complexity.
3Stability of the object's composition
If the cast billet is fed into the working gauge at an angle to the extrusion axis, then uniformity of mechanical properties improves, but device complexity increases
Solution Approach 1:
The patent employs a dynamic guidance system that can adjust the feed angle of the cast billet relative to the extrusion axis. The guidance device is designed to be reconfigurable, allowing optimization of the feed angle for different product specifications while maintaining operational simplicity through standardized adjustment mechanisms.
4Duration of action of stationary object
If gaps are maintained between roll surfaces and die to prevent steel-to-steel contact, then service life of rolls and die increases, but manufacturing precision decreases
Solution Approach 1:
The patent introduces a thin layer of metal or alloy as an intermediary between the steel roll/die surfaces and the workpiece. This intermediate layer prevents direct steel-to-steel contact and wear while maintaining sufficient dimensional control through proper layer thickness management and surface finish control.
Solution Approach 2:
The patent optimizes the gap dimensions between roll surfaces and die to specific ranges that prevent metal-to-metal contact while preserving manufacturing precision. By carefully controlling gap width and position through adjustable mechanisms, the system extends component life without sacrificing product dimensional accuracy.
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 enhances the quality and uniformity of long products, reduces energy consumption, extends the service life of rolls and dies, and minimizes metal return loss by maintaining optimal temperature and reducing friction, resulting in improved mechanical properties and efficiency in the rolling and extruding processes.
Implementation Method 1
a temperature control device of the cast billet installed upstream of the rolls
Implementation Method 2
a temperature control device of the cast billet installed upstream of the rolls
Implementation Method 3
grooved roll and a finned roll forming a working gauge... labyrinth coupling of the said rolls with each other
Data Source
AI summary
A method for combined rolling and extruding of cast billet is proposed. When implementing the method for combined rolling and extruding of metals or alloys, a cast billet with a predetermined temperature is fed to the working gauge, in which it is rolled and then to the die, through which the cast billet is extruded. When the cast billet is fed into the working gauge, a cladding layer of metal or alloy is created on the surfaces of the rolls by extruding the cast billet through the gaps formed between the surfaces of the rolls and the die. This invention makes it possible to improve the quality of the resulting products, as well as to increase the efficiency of the process as a whole.